PAPER PLANT (WRITING AND PRINTING PAPER)
[EIRI/EDPR/7840] J.C. 7689XL
INTRODUCTION
Paper form a cammodity of prime in partance to day from the parts of view of mass cammunication, education and industrial and economic growth. The art of paper making was first discovered in China in and around 2nd century. B.C. pan where it travelled slowly west ward and reeched the prantiens of Europe. By the end of 14th century, a mamber of paper mill existed in Europe, parti culary in Apain, Itoly, Frince and Germany. The invention of printing in 1956 brought a vastly in creased demand for paper and paper-manufacturing was introduced to England. America followed in 1690.
Agricultral residues, such as hagasse, rice husk, wheat husk jute sticks, grasses etc. are fast becomming popular materials for paper making. considerable aattention is being given to the utilisation of various agricultural by products for preparing pulp for paper manufacture landable efforts are being make in this direction.
Paper production requires a disintegration of the bulky fibraes material to individual or small agglomacrate fibres.
This is called pulping. The ideal fibre for high grade paper should be long, high in cellulose content and low in ligrin content. Most ideal raw materila for paper products is bamboo. Other saurces are bagasse and hardwoods like jute stick must be developed and good quality paper pulp make by blending with bamboo fibre.
Over recent years, the emergencies of mini paper plants on a reality seems to hold the promise of adding new horizans to the development and growth of Indian paper industry. In may be noted with concern that the large sector of this in dustry for quite sametime, has failed to sustain any appreciable groth dul to various factors eg. The plant being highly capital intensive low rats of rturn and the raw materil bttlenecks etc. mini paper plants are riewed as an effective remedy to the current ailments of the paper industry as they in volve much less capital cost and are proved to be tecnically feasible and economically viable these plants can be erected on the basis of fully indiyenous expertisek, knowhow and machinery. Moreover, they after an effective means of lasing comiderably the burden an the conventional raw naterials.
COST ESTIMATION
Plant Capacity 250 MT/Day
Land & Building (1,20,000 sq.mt.) Rs. 27.65 Cr
Plant & Machinery Rs. 80.56 Cr
Working Capital for 3 Months Rs. 18.48 Cr
Total Capital Investment Rs. 138.91 Cr
Rate of Return 47%
Break Even Point 40%
CONTENTS
INTRODUCTION
1. SHORTAGE OF FIBROUS RAW MATERIAL
2. HIGH PROCES AND SHOTAGE OF CHEMICALS
NEWS PRINT PAPER
USES AND APPLICATION
BESIDES, THE END USE OF PAPER AND PAPER PRODUCTS ARE,
USES OF NEWS PRINT
B. I. S. SPECIFICATION
B.I.S. SPECIFICATION FOR WRITING AND PRINTING PAPERS
SCOPE
TERMINILOGY
REQUIREMENTS
PACKING AND MARKING
CRITERIA FOR CONFORMITY
DETAILED MARKET SURVEY
INDIAN PAPER INDUSTRY SCENARIO
INCREASE IN AGRICULTURAL PRODUCTION
THE BOVE NCRESE N PRODUCTON SHOULD COME FROM:
CHEMICALS REQUIRED FOR PULP & PAPER MILLS (IN GENERAL)
CAUSTIC SODA (NAOH)
CHLORINE
HYPOCHLORITE
ALUM
ROSIN
STARCH
CHINA CLAY
TALC
OTHER CHEMICALS
MANUFACTURING PROCESS OF PAPER (WRITING/PRINTING)
FROM PULP AND WASTE PAPER
BLEACHING:
SCREENING OF THE PULP
WASTE PAPER PULPING
PULP BEATING & REFINING
SIZING & LOADING
REFINING
PAPER MAKING AND FINISHING
EFFLUENT DISPOSAL
FLOW SHEET OF MANUFACTURER OF PAPER
FORMING OF WET WEB, PESSING THE WET SHEET & DRYING
THE SHEET
SPECIAL UTILITY AND LOCATION OF THE PLANT
RAW MATERIAL SUPPLY
WATER SUPPLY POSITION
TRANSPORTATION FACILITIES
WATER DISPOSAL
ELECTRIC POWER SUPPLY
DETAILS OF WASTE PULPING
THE DIFFERENT SYSTEMS MAY BE DESIGNED AS FOLLOWS:-
SCREENING AND RIFFLING:-
WASHING:-
BLEACHING:-
BEATING:-
SHEET LIFTING:-
PAPER COUCHING:-
PAPER DRYING:-
PAPER PRESSING:-
PAPER CLEANING:
PAPER GLAZING:-
SURFACE SIZING:-
DEINKING OF WASTE PAPER
SECONDARY FIBER PULPING:-
SECONDARY FIBER PULPING SYSTEMS
THERE ARE TWO BASIS STEPS IN THE DEINKING.
ALL DEINKING SYSTEMS HAVE THE FOLLOWING STEPES:-
VERTICAL CIRCULATION DEINKING WITH BREABEN BEATER
THERMOMECHANICAL PROCESS:
TYPICAL PROCESS
STOCK OR PULP MAKING:
REFINING (JORDAN REFINER):
PAPER MAKING AND FINISHING:
PROCESS FLOW CHART FOR NEWS PRINT PAPER
PULP PRODUCTION TECHNOLOGIES
CHEMICAL PULP PRODUCTION
1. COLLECTION AND STORAGE OF FIBRES AND WASTE PAPER
COLLECTION & STORAGE OF WASTE PAPER
WASHING
SCREENING
CLEANING
BLEACHING
STOCK PREPARATION
THE HYDRAPULPER
SIMPLE PULPER, BATCH OR CONTINUOUS PULPING
BEATING
BEATERS
REFINING
CONICAL REFINERS
DISC REFINERS
FILLER, SIZING AND COLORING AGENTS
SCREENING
CLEANING
STOCK CONTROL
CONSISTENCY REGULATORS
THE PAPER MACHINE
FORMATION AND DRAINAGE
PRESSING
PRESSES
DRYING
REELING WINDING AND SHEETING
A CALENDER AND POPE REEL ARRANGEMENT ARE SHOWN IN FIGURE.
WINDERS
CUTTERS
CYLINDER MOULD MACHINE
MACHINE CONVERTING
EFFLUENT DISPOSAL
POLLUTION CONTROL IN PULP AND PAPER INDUSTRIES (IN DETAIL)
PROCESSES AND CHARACTERISTICS OF LIQUID EFFLUENTS
CHEMICAL CHARACTERISTIC OF EFFLUENT FROM A LARGE SULPHATE
(KRAFT) PULP AND PAPER MILL USING CHEMICAL RECOVERY
POLLUTION CONTROL FOR LIQUID EFFLUENTS
INPLANT MEASURES
PROCESS CHANGES
BIOLOGICAL TREATMENT
PERFORMANCE OF SOME BIOLOGICAL TREATMENT METHODS
PERFORMANCE OF PILOT PLANT AERATED LAGOON (ALL VALUES
EXCEPT PH ARE EXPRESSED AS MG/1)
LAND REQUIREMENTS, CAPITAL AND RUNNING COSTS FOR WASTE TREATMENT FROM A 200 TONNES/DAY PLANT
AIR POLLUTION
CONTROL METHODS
REMOVAL OF PARTICULATE MATTER FROM EFFLUENT GASES
PRELIMINARY METHODS OF SEPARATION
GRAVITY SETTLING CHAMBER
CLONE SEPARATORS
OTHER MWTHODS
ECTROSTATIC PRECIPITURS
REMOVAL OF SULPHUR DIOXIDE
THIS IS DONE BY -
SUPPLIERS OF CHEMICALS USED
SODA ASH
CAUSTIC SODA
CHLORINE LIQUID:-
ALUM:-
STARCH:-
ROSIN:-
SUPPLIERS OF PLANT & MACHINERY
PAPER PLANT EQUIPMENT
SUPPLIERS OF RAW MATERIALS
PULP: -
PRESENT MANUFACTURERS OF PULP
PLANT LAYOUT
RAW MATERIALS CALCULATIONS
TOTAL RAW MATERIALS REQUIRED
DETAILS OF PLANT & MACHINERY
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)