1. Paper Industry
Presented By-
Er. Sanyam S. Saini
ME (I&CE) (Regular)
2012-14

2. Introduction
 The pulp and paper industry converts wood or recycled fibre into
pulp and primary forms of paper.
 The pulp and paper industry is one of India's core sector industries.
 Pulp mills separate the fibres of wood or from other
materials, such as rags, wastepaper or straw in order to create
pulp.
 Paper mills primarily are engaged in manufacturing paper from
wood pulp and other fibre pulp, and may also manufacture
converted paper products.
 The socio-economic importance of paper has its own value to the
country's development as it is directly related to the industrial and
economic growth of the country.

3. Indian Paper Industry in Global Prospective
 World Paper & Board consumption is dominated by three major
regional blocks- North America, Western Europe & Asia.
 Global paper production is 340 million tons.
 India consumes nearly 5% of the Asian and 1.6% of the worlds
consumption of paper and paper board
North
Rest, 9.0% America, 31.0%
Europe, 28.0%
India, 1.6% Asia, 30.4%
Source : ICRA report to IPMA : 2011

4. Paper Industry at a Glance
Total number of Pulp & Paper Mills 706
Wood Based 33
Agro Based 165
Recycled Fiber Based Mills 508
The industry is fragmented with capacities ranging from 2 to 800 tonnes per day.
Production million tonnes
P&B 6.0
Newsprint 0.8
Installed Capacity of Mills 8.3
Source : ICRA report to IPMA : 2011

5. Generalized of Paper Making from different
types of Raw Materials

6. Typical process for paper Manufacture
Raw Material
Raw Material, Water Preparation Waste Water
Section
Chemicals ,Water Pulping Section
Pulp Washing &
Water Waste Water
Bleaching Section
Stock Preparation
Alum, Rosin, Water System
Additives Paper Machine Waste Water
Finished Paper

7. Different Industrial processes
Based on the type of raw material used, the manufacturing processes
are classified into:
 Wood Based Pulp and Paper manufacturing Process
 Agro residue based Pulp and Paper manufacturing Process
 Secondary fiber based Pulp and Paper manufacturing
Process

8. Paper Manufacturing
Step 1- Raw Material Preparation:
Chip
Debarker Chipper Digester Blow Pit
Storage

9. Debarker

10. Chipper

11. Digester

12. Practical Digester

13. Various Methods of Pulping:
Step 2- Pulping:
 Mechanical Method of Pulping
 Chemical Method of Pulping
 Semi Chemical Method of Pulping

14. Various Methods of Pulping:
Mechanical Pulping
 Mechanical pulping uses mechanical abrasion to separate
cellulose fibers which are held together by lignin.
Chemical Pulping:
 Chemical pulping achieves fiber separation by dissolving
the lignin.
Types of Chemical Pulping:
There are three chemical pulping methods…
 Soda Chemical Pulping
 Kraft (or Sulfate) Chemical Pulping
 Sulfite Chemical Pulping

15. Types of Chemical Pulping:
Soda Pulping:
 Soda pulp is the original chemical pulp and is produced by
cooking chips of deciduous woods in a solution of caustic soda
under pressure.
Kraft(Sulfate) Pulping:
 In the Kraft process, an aqueous solution of sodium hydroxide
and sodium sulfide, known as white liquor, selectively dissolve
the lignin and make it soluble in the cooking liquid.
Sulfite Chemical Pulping:
 Sulfite pulping uses sulfurous acid and an alkali to produce
pulps of lower physical strength and bulk, but exhibits better
sheet formation properties.

16. Types of Chemical Pulping:
Semi-Chemical Pulping:
 Semi-chemical pulps are essentially mechanical pulps that
have been pre-treated with a sulfite or sodium hydroxide
liquor to improve breakdown and reduce energy
requirements during processing.

17. Paper Manufacturing
Step 3: Pulp Washing
 After the wood is pulped, the pulp that is created is washed to
remove the dissolved lignin and chemicals.
 The washing process occurs at high temperatures which generates a
large volume of exhaust gases containing hazardous air pollutants
which are released to the atmosphere.

18. Batch Washer

19. Continuous Washer

20. Paper Manufacturing
Step 4: Pulp Bleaching
 After washing, if a white product is desired, the pulp must
be bleached to remove color associated with remaining
residual lignin.
 Typically, in the bleaching process, the bleaching chemicals
are injected into the pulp, and the resulting mixture is
washed with water.

21. Unit operations in a bleaching stage
Steam Chemical Water
Mixer Mixer Reactor Washer
Washed
Washed
pulp
Pulp
from
from
Next
Previous
stage Effluent

22. Bleaching Tower

23. Bleached and unbleached pulp:

24. Waste paper pulping
 Recycled paper (Waste), newsprint and magazine is charged
in Hydraulic Pulper with adding water and it is being
processed till waste paper is converted into slurry form with
high consistency pulp. This is also known as Hydrapulper.
 Then it is transferred to machine chest where addition of
dye, chemical takes place. This pulp then is fed to the machine
chest. This machine is known as Blend Chest.

25. Hydro pulper used for pulping
wastepaper/recycled material

26. Hydropulpers

27. De-inking Process
 Deinking is a recycling technique that can produce high
quality recycled pulp from recovered papers.
 Flotation Deinking which makes ink particles hydrophobic by
means of a collector in a flotation cell. The air bubbles
generated at the bottom of the cell carry the ink particles to
the surface where they are confined in foam which is
removed.

28. Conventional Chemical Washer

29. Paper Machine Overview
(Fourdrinier-type paper machine)

30. Paper Machine
 The blended pulp is again centricleaned to remove impurities and
finally fed to the paper machine through a head box.
 From the dewatering and paper making angle, the machine has
three principal stages:
i. The gravitational and vacuum dewatering stage (wire part)
ii. The mechanical dewatering stage (press rolls part)
iii. The thermal drying stage (indirect steam dryers)
 On the wire part of the paper machine, the dewatering of pulp takes
place by gravity and vacuum.
 The water from the wire mesh is collected in a fan pump pit and is
continuously recycled to dilute the pulp fed into the paper machine
centricleaner.

31. Paper Machine
 After the wire part, the edge cutting operation is carried out to
obtain paper of a definite width.
 The edge cuts of the pulp web falls in the couch pit and are recycled
to the machine chest.
 Towards the end of the wire part of the machine, the consistency of
pulp rises to about 20 per cent.
 Further dewatering is carried out by press rolls to raise the
consistency to about 55%.
 The paper is finally dried through an indirect steam dryer to about
94% solids and is collected in rolls as the final product.

32. Paper Machine Section

33. Environmental Impact of Pulp & Paper
Process Industries
 Pulping often releases a range of pollutants, including organic
products which cause eutrophication in water, aluminum salts and
sometimes also generation of sulphur dioxide.
 When bleaching is carried out with chlorine or hypochlorite, it may
generate dioxin. These pollutants have direct impacts on freshwater
and marine ecosystems near pulp mills.
Air Emissions
 Air pollution mainly occurs
from digesters blow
tanks, steam boilers chemical
recovery boilers

34. Environmental Impact of Pulp & Paper
Process Industries
Solid waste
 Solid waste is generated in the form of sludge, ash, wood
waste, screening, centricleaner rejects, sand and grit.
 The major concerns with these wastes is their disposal.

35. Conclusion

36. Thank You