CPPRI News Bulletin

» Research Activities

A. Plan Scheme Projects

1. Preservation of strength properties during pulping and bleaching
Studies on oxygen treatment of bamboo pulp for production of high brightness pulp were carried out. The medium kappa pulp was treated with oxygen to reduce kappa before bleaching. Oxygen treated pulp was bleached to high brightness using dioxide.

2. Studies on the Improvement of Paper Quality through Fractionation/Refining and Furnish Optimization
After laboratory evaluation of mill pulp containing mixed hardwood and bamboo with respect to their fractionation and strength properties, pulp samples from the commercial fractionator were collected and studied in the laboratory. Pulp from each stream i.e. inlet pulp, long fraction pulp and short fraction pulp was processed individually for their fraction, strength and printing properties. The possibilities of making different grades of paper from different fractions of pulp were studied in the laboratory by making the multi layer sheets and testing their different properties. Further work is in progress.

3. Energy Conservation in Pulp & Paper Industry - Process Integration & Optimisation
Main objective of the project is "To further reduce the energy usage in Paper Industry through Process Integration and Optimization and through adoption of advanced techniques such as Pinch Analysis". A team of CPPRI scientists and experts from TP-KTI visited a selected integrated pulp & Paper mill for collection of data from Evaporator section, Digestor section and Utility section and discussion with mill personnel. Most of the preliminary studies have been completed and detailed energy & material balances of evaporator section; digester and utility section is also completed. The draft report on Pinch Analysis has been prepared and submitted to the selected mill.

4. Modification of Black Liquor Properties - Effect of System Closure
CPPRI's team visited a wheat straw based mill for detailed studies on accumulation of NPE;s in recovery section of mill, Samples were collected and analyzed at CPPRI ., Mass & material balances were prepared and experiments on Evaporative crystallization were carried out to reduce the NPE's from chemical recovery loop with encouraging results

5. Determination & Quantification of Odorous Emissions In Pulp & Paper Mills - Their Reduction/Elimination
The objective of this project is to determine and quantify different malodorous gases generated in pulp and paper mills and also to generate data based information on the level of various malodorous gases at different sulfidity and temperature as used by the industry. Various means to reduce or eliminate these malodorous pollutants will also be looked into.

The studies were continued using the conventional raw material used by large pulp and paper industry i.e eucalyptus and bamboo. Pulping experiments were carried out in laboratory digester at different sulfidity levels and temperatures. Preliminary studies indicate high amount of dimethyl sulfide and methanol emissions during the digester blow. Sulfidity level and temperature also play a key role in generation of high level of mercaptants and as such should be optimized for reducing their level. Further studies with other raw materials are also being planned. Process for filing a patent for the development of NCG 's monitoring kit is under progress. Testo 400, equipment was procured which can measure the velocity of gases up to 60m/sec. It also measures CO2 , CO, humidity, temperature and ambient air quality.

6. Identification and Removal of contaminants for effective processing of Recycled Fiber:
Extensive laboratory studies have been conducted with different ONP/OMG furnish ratio and with different non-ionic surfactants. The right furnishes of ONP/OMG to be used and the conditions during pulping and flotation under which it has to be used have been successfully established. This together with the optimized addition point dosage of the selected non-ionic surfactant has resulted in significant brightness gain to the tune of +10 points. It has been also found that the aging of ONP/OMG is a serious threat to the ultimate brightness obtained. Laboratory studies on post bleaching of the deinked pulp to improve the ultimate brightness of newsprint & writing/printing paper employing oxidative/reductive sequence in single and multi stage are underway.

7. Demonstration of Color Reduction Technologies for Pulp & Paper Mill Effluent:
Electro-flocculation studies conducted on bleached effluent collected from wood based mill has shown reduction to the tune of 96% for color, 90% for lignin, 86% for COD, 88% for BOD and 82% for AOX. Based on laboratory findings the process has been found to be economically viable, which further needs to be established on pilot scale on continuous process. Further work is concentrated to make the process a continuous one.

8. Enzymatic Deinking of Recycled fibres:

The objective of this project is development of the enzymatic deinking technology for recycled fibres using various enzyme combinations for adaptation of the technology in Indian Paper Industry. Enzymatic deinking studies with cellulase enzymes and enzyme combinations were continued on mixed office waste (MOW) and Laser waste for the optimization of process parameters. Four cellulases (indigenous & imported) were evaluated on mixed office waste (MOW). Two enzymes showed encouraging results in terms of both brightness improvement and dirt count reduction. The studies are compared with conventional chemical deinking. Preliminary results showed the effluent quality was improved in terms of COD and BOD of the enzyme deinked pulps when compared to conventional deinked pulps.

B. Cess Funded Projects

1. Energy Performance Evaluation and Optimisation in Pulp & Paper Industry
The Energy Audit studies were conducted in five more Pulp & Paper mills from different categories in the month from April to June 2003. So far 12 mills have been covered under the project activities.

¤ M/s Ballarpur Industries Ltd., Chandrapur (Maharashtra)
¤ M/s Shelavi Pulp & Paper Mills Pvt. Ltd., Mehsana (Gujarat)
¤ M/s Karan Paper Mills, Mehsana (Gujarat)
¤ M/s Yash Paper Ltd., Darshanagar, Faizabad (U.P.)
¤ M/s Plaza Papers Pvt. Ltd., Village Ghunna, Saharanpur

Data collected during the energy audit have been analysed and based on it reports containing respective energy conservation proposals have been prepared and submitted to all the mills.

Following mills have also shown their keen interest in the energy audit methodology of CPPRI energy team

¤ M/s Orient Paper Mills, Amlai
¤ M/s Ballarpur industries Ltd., (Unit Shree Gopal), Ymunanagar
¤ M/s The Sirpur Paper Mills Ltd., Kaghaznagar (A.P.)
¤ M/s Madhya Bharat Paper Mills Ltd., Champa

The Itinerary for conducting energy audit has been submitted to the mills and audit in these mills will be conducted in the month July - August, 2003.

2. Calibation and Intra Laboratory Quality Assesment Service for Pulp and Paper and Allied Industries (Cess/Ipma Sponsored):
The different mills have been asked to send the paper samples for evaluation. These samples will be evaluated for inter laboratory, intra laboratory statistical evaluation. Work is in progress.

3. Studies on Benchmarking / Input Norms in Pulp & Paper Industry
CPPRI during last few years CPPRI has conducted exercises on resource recovery & conservation in Pulp & Paper Industry. The studies on raw material, energy, water conservation and optimization of chemicals input to the processes have produced excellent results. However, an integrated study on bench marking / input norms for the Pulp & Paper Industry in India has not been made so far. In view of this the project has been initiated to provide norms to optimize the basic inputs such as fibre, energy, water and chemicals in Indian Pulp & Paper Industry. This will also help to identify their process efficiency and achieve cost competitive production.

In this connection Input data from representative mills from different categories such as forest based, agro based, waste paper based, newsprint and rayon grade based has already been collected and it is now being analysed after updation / correction from the mills to get best results of the study.

4. Demonstration of enzymatic prebleaching in a pulp & paper Mill
Under the project activities, the Institute proposes to demonstrate the biobleaching process on mill scale for improving the product quality and environment. After the investigation of the process conditions and facilities available in the identified mill Seshasayee Paper & Boards Ltd. Institute proposed for one month mill trail. CPPRI received good response from various enzyme suppliers along with details of quality & cost of the enzymes.

5. Availability & Utilization of Waste Paper-Follow up Activities - visit of Indian Delegation.
As a follow-up of the recommendations of the above project, a six member delegation comprising of nominated representative each from CPPRI and various industry association, visited France from 20th May - 24th May 2003 and Japan from 31st May - 4th June 2003 to study the prevailing practices for waste paper/recovered paper collection, sorting, grading, distribution and processing in these countries. The nominated members were :

¤ Sh. Raji Philip, INMA
¤ Sh. V. D. Bajaj, IPMA
¤ Sh. R. C. Rastogi, IRPMA
¤ Sh. J. K. Gupta, IARPMA
¤ Sh. R. N. Moorthy, IPMA
¤ Mrs. Rita Tandon, CPPRI

The delegation visited mills and organization including Waste Paper sorting plants and R & D Centre during the course of the study tour.

Following is the list of various organizations visited.

1. R & D organization

(i) Centre Tecnique Du Papier (CTP), GRENOBLE, FRANCE.

2. Paper Mills

(i) UPM Group's Chapelle Darblay Mills, Kymmene, FRANCE.
(ii) M/s Les Papeteries Emin Leydier, FRANCE.

3. Waste Paper Sorting Plants

(i) Communaute Urbaine Creusot Montceau, FRANCE.
(ii) Le Centre de tri d'Athonor, FRANCE.
(iii) Saikyo Shigenka Centre, JAPAN

4. Organization/Groups associated with Waste Management

(i) Eco-Emnallages, Private organization.
(ii) RAVIPAC, Association of the French Paper Recycling Industry.
(iii) Confederation of the French Pulp, Paper and Board Industry (COPACEL), FRANCE.

6. Detoxification of Bleach Plant Effluent for Recycling & Reuse:

In continuation to the project studies, bleach plant effluent (combined & individual stage) were collected from an agro-based mill and characterized for different pollutional parameters. The identification of different chloro phenolic compounds was carried out by gas chromatograph. The bleach effluent were fractionated into various fractions by ultrafiltration using variable size membranes (1000, 3000, 10,000, 30,000 and 100,000 D). The permeate and concentrate obtained were characterised for pollutional parameters including toxicity and AOX and their aerobic biodegradability was also evaluated. The mass balance of AOX fractions of different molecular wt. was also done. LC50 bioassay studies were also carried out with C & E stages and combined bleach plant effluent in lab scale aquariums using fish.

C. Sponsored Projects

1. Biotechnological Application Of Enzymes For Making Paper Pulp From Green Jute / Kenaf:
The IJO/UNDP sponsored project is on progress. Under this project studies of jute kraft and soda pulp were bleached using different bleaching sequences viz. CEH, C/DEH, C/DEpH, C/DEopH. The pulp samples after bleaching were analyzed for brightness, viscosity etc. The effluent samples were sent for analysis of various effluent characteristics.

2. Color Removal from Black Liquor generated From Agro Based Pulp & Paper Mills CPCB Sponsored Project-
Final report has been submitted to CPCB and a proposal has been submitted to CPCB for setting up of a demo pilot plant of 1 m3/hr capacity in a agro based mill to study the techno economic feasibility of the process for treating black liquor.

3. Revision of Comprehensive Industry Documents (COINDS) for small & large scale pulp & paper industries (CPCB sponsored project)
CPPRI has been assigned the task to revise the comprehensive industry documents (COINDS) for small and large-scale pulp & paper mills prepared by CPCB in early 1986 & 91 respectively. The main objective of the task is to review and revise the environmental discharge norms including potential of cleaner production options in Indian pulp & paper industry.

Under the project a team of scientists conducted preliminary visits to M/s ITC Bhadrachalam & Bilt - APR, Kamlapuram for collection of general & technical information related to process, itechnologies employed, sources of waste discharges (liquid, air emissions and solid waste) and their management practices .The detailed mill visit to these mills have been planned in mid July.

4. Life Cycle Assessment Study in Pulp & Paper Mills in India (IARPMA sponsored Project)
The main objective of the project is to increase the productivity in the paper sector and improve the environment as a whole by identification of gaps between the existing operating conditions and the international benchmarks. LCA study will be helpful to the industry in sustainable development and provide opportunities to increase process efficiency and thus make them able to compete in global market.

Under the project the the analysis of effluents, solid wastes and air samples and compilation of data collected during the visits to M/s Star Paper Mills Ltd, Saharanpur & Tehri Pulp & Paper Mills, Muzaffarnagar were completed and the results of studies conducted were submitted to IARPMA for their further simulation with the software. Joint meetings between CPPRI scientists & IARPMA officials were held in April & June 2003 to discuss the project progress and the analytical results.

5. Evaluation Of Hardwood Acacia Nilotica (Desi Babul) For Paper Making
A project entitled "evaluation of hardwood Acacia nilotica (desi babul) for paper making", was sponsored by M/S J. K. Corp Ltd (CPM) Surat. The aim of the project was chemical analysis, pulping and bleaching of Acacia nilotica. The project is successfully completed and final report has been submitted to the mill.

6. Pulping and Bleaching Of Oil Palm Fiber
A project entitled "pulping and bleaching of oil palm fiber", was sponsored by M/S Chanderpur Works, Yamunanagar.. The aim of the project was to evaluate the raw material (oil palm fiber) for pulping and bleaching. The project is successfully completed and final report has been submitted to the sponsor.