1. Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study

2. Yash Papers Ltd. Yash Papers established in the year 1981 and is located in Faizabad, Uttar Pradesh We are agro based and use bagasse, wheat straw, gunny bags and a portion of softwood as a raw material. The production capacity of the plant is 39,100 MT per annum We have three MG paper machine with capacity of  PM 1- 30 MT/day  PM 2- 30 MT/day  PM 3- 70 MT/day We have a Recovery Boiler of 140 MT Dry Solids/day capacity and Power Plant of 6 MW capacity. We make specialty and packaging grades of paper.

3. Objective  To optimize the fiber properties  To produce a paper with enhanced fiber properties and hence value addition to existing product basket  To reduce energy consumption and long fiber consumption & hence reduction in cost of production

4. Approach To achieve better fiber strength properties we modified & optimized our refiner operations Installation of online measurement & control systems and automation Consistency optimization Flow Optimization Different grades of Long Fiber Optimization

5. TDR Overview

6. TDR Control Panel

7. Recirculation 0 SR15202548 Recirculation Time 3.30 hrs.4 hrs.5 hrs.8 hrs. Cy%4.2 Burst Factor16.8918.3835.0140.41 Tear Factor103.70137.03140.86104.22 Load 21”/17” (Amp) 180/160

8. Consistency Optimization

9. Consistency Trial Consistency%4.54.23.93.53.3 Burst Factor29.42624.422.935.8 Tear Factor196.9185187.5191.5190.4

10. Observation The Burst Factor increased by reducing the consistency of the pulp without affecting other properties

11. FLOW OPTIMIZATION

12. Flow@ 3.3% Consistency FlowInitial20 m 3 /hr After 21” Refiner 30 m 3 /hr After 21” Refiner 40 m 3 /hr After 21” Refiner 50 m 3 /hr After 21” Refiner MT/hr0.660.91.31.6 0 SR2120 19 Burst Factor11.842.939.63735.8 Tear Factor150.4173.7200168.6168.1 Refiner load 21”/17” (Amp) 180/16090/91120/100160/155180/163 Pressure (kg/cm 2 ) 1.12.82.42.11.9

13. Flow@ 3.7% Consistency FlowInitial20 m 3 /hr After 21” refiner 30 m 3 /hr After 21” refiner 40 m 3 /hr After 21” refiner 50 m 3 /hr After 21” refiner MT/hr0.71.11.51.9 0 SR20181715 Burst Factor9.236.333.83122.9 Tear Factor101.4204.7206.3191.9173.2 Refiner load 21”/17” (Amp) 180/16085/92120/126165/136170/164 Pressure (kg/cm 2 ) 1.22.52.31.91.8

14. Flow @ 3.9% Consistency FlowInitial20 m 3 /hr After 21” Refiner 30 m 3 /hr After 21” Refiner 40 m 3 /hr After 21” Refiner 50 m 3 /hr After 21” Refiner MT/hr0.81.21.62.0 0 SR1816 15 Burst Factor9.933.128.627.624.4 Tear Factor91.2239.4202.8187.3178.5 Refiner load 21”/17” (Amp) 180/16082/90107/100133/125150/160 Pressure (kg/cm 2 ) 1.12.82.42.11.9

15. Flow @ 4.1% consistency FlowInitial20 m 3 /hr After 21” Refiner 30 m 3 /hr After 21” Refiner 40 m 3 /hr After 21” Refiner 50 m 3 /hr After 21” Refiner MT/hr0.81.21.62.1 0 SR19181715 Burst Factor10.735.334.63226 Tear Factor105.4200192.6176.2157.5 Refiner Load 21”/17” (Amp) 180/160100/104120/126130/132140/137 Pressure (kg/cm 2 ) 1.22.41.91.81.5

16. Flow @ 4.5% Consistency FlowInitial20 m 3 /hr After 21” Refiner 30 m 3 /hr After 21” Refiner 40 m 3 /hr After 21” Refiner 50 m 3 /hr After 21” Refiner MT/hr0.91.41.82.3 0 SR17 1615 Burst Factor9.731.730.329.425.6 Tear Factor106.2191.5213.3196.9154.3 Refiner Load 21”/17” (Amp) 180/160180/100120/124135/137140/136 Pressure (kg/cm 2 ) 1.12.52.11.81.5

17. Trends BF Cy% BF Cy% BF Cy% BF Cy%

18. Observation At any particular consistency, strength property is increasing with reduced flow rate level At any particular flow rate, it is observed that with decreasing stock consistency strength properties are better

19. Grades Selection & optimization of Long Fiber

20. Burst Factor @ 3.3% Consistency Flow (m 3 /hr)Grade 1Grade 2Grade 3 2044.735.270.5 3041.233.454.8 4039.032.153.1

21. Burst Factor @ 3.9% Consistency Flow (m 3 /hr)Grade 1Grade 2Grade 3 2036.332.168.4 3033.930.650.7 4032.229.639.2

22. Burst Factor @ 4.2% Consistency Flow (m 3 /hr)Grade 1Grade 2Grade 3 2034.035.066.1 3036.630.650.8 4037.728.442.5

23. Trends BF

24. Observation Grade 3 of long fiber shows better strength properties as compared with other two grades

25. COST BENEFIT

26. Cost Benefit By using Single pass refining we achieved a reduction of 1% long fiber in the papermaking resulting in a saving of Rs. 1.18 crore The energy consumption observed decreased in single pass refining as compared to recirculation The paper produced through single pass refining shows better strength properties as compared to recirculation The paper thus produced added value by increased NSR

27. Cost Benefit by Softwood Reduction Serial No.ParametersSeptemberOctober With CirculationSingle Pass 1Softwood15%14% 2Bagasse Tear42.041.6 3Bagasse Burst Factor 16.0715.82 4Savings15.0-14.0 = 1% 5Softwood Saving/Month 18 Tons/Month 6Saving/Year216 Tons/Year 7Cost216*55000 = 1.18 Crore

28. Running Load Refiner running Load Data RefinerCurrent (Amp)Power (Kwhr) 21”180109.73 17”16097.54

29. Power Saving Serial No.ParticularsRecirculationSingle Pass 1Running Hours13.256.97 2Batch Size50 m 3 @ 4.2cy%= 2.10 MT 30 m 3 /hr. @ 3.3 cy%= 0.99 MT 3Recirculation Time4 hrs. 4Net Output2.14*(13.25/4)= 6.95 MT 0.99*6.97= 6.9 MT 5Power Consumption/Day (Kw/Day) 2746.321444.71 6Power Consumption/year (Kw/Year) 906285.6476754.3 7Power Consumption Saving/Year (Kw) 429531.3 8Cost Saving (Per Unit Cost- Rs.3) Rs. 12,88,593

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