Board Mill Research Articles

Simulation Model of Precast Concrete Element Delivery on Time and Operational Costs of the Precast Yard in the Board Mill Construction Project

Simulation Model of Precast Concrete Element Delivery on Time and Operational Costs of the Precast Yard in the Board Mill Construction Project

An Analysis of Operating Performance of Selected Paper Companies in India

Purpose: The aim of this research work is to analyze and compare profitability performance of selected paper companies in India. Approach/Methodology/Design: An analytical study method is employed in this research work by relying on secondary data. In this research work 12 paper companies are selected as a sample based on their higher net sales and the study period are last10 financial years from 2012-13 to 2021-22. Ratio Analysis is used as an accounting tool in which six profitability ratios are employed. One-way ANOVA technique of parametric test is used as a statistical tool to identify the difference among sample means. Findings: The major finding of the research work indicates that in all the selected paper companies the profitability performance of shows fluctuating trend during the study period of 10 years. The overall performance was good and satisfactory in Satia Industries Ltd., JK paper Ltd., Seshasayee Paper and Board Ltd. and NR Agarwal Industries Ltd. and it was low and dissatisfactory in Orient Paper & Industries Ltd. and Astron Paper & Board Mill Ltd. for all the selected profitability ratio during the study period. The results of statistical test revealed that in gross profit ratio, operating profit ratio and return on assets ratio formulated null hypotheses are rejected and in net profit ratio, return on net worth ratio and return on capital employed ratio formulated null hypotheses are accepted. Originality/value: In this research work profitability analysis is carried out which is helpful to know the profitability performance of selected paper companies. The result would help investors to make right choice of investment in selected companies. It would also identify that how efficiently a business can generates profit and value for its shareholders from its sales or operations, shareholders' fund or balance sheet’s assets.

Kinetic and isotherm insights of Diclofenac removal by sludge derived hydrochar

Recently, hydrothermal carbonization emerges as the most viable option for the management of solid waste with high moisture content. Sludge derived hydrochar is used as an adsorbent for emerging contaminants or micro-pollutants in the domain of sustainability. Current study demonstrates the KOH activation of hydrochar produced from paper board mill sludge and evaluates its removal potential of a Non-steroidal anti-inflammatory drug, Diclofenac from aqueous solution. The activated hydrochars exhibited porous, spherical micro-structures with higher fraction of oxygenated functional groups paving way for the efficient adsorption of Diclofenac. The effect of initial Diclofenac concentration and contact time was ascertained using adsorption kinetics and isotherms. The adsorption kinetics exhibited second-order reaction for all adsorbents indicating higher coefficient of determination (R2 > 0.9). The Diclofenac adsorption on hydrochars followed Langmuir isotherm model with the post-activated hydrochar recording a highest adsorption capacity of 37.23 mg g−1 in 40 mg L−1 initial Diclofenac concentration at 15 h equilibrium time.

Production and Characterization of Paper Board Mill ETP Sludge Derived Hydrochar

Hydrothermal Carbonization an emerging technology for the conversion of biomass into carbon rich materials called as hydrochar. In this study, the paper board mill ETP sludge has been used for the production of hydrochar. The characterization of point of zero charge, Heavy metals, proximate and ultimate constituents, structural morphology (SEM), and molecular surface functionalities (FTIR) were also analysed. The results of Hydrochar showed slightly acidic pH (6.40), EC (1.33), and the pHPZC (point of zero charge) of 7.8 and the heavy metals content were found to be below detectable limit. FTIR analysis revealed that, the produced hydrochar have oxygen containing functional groups (-OH, C-O-C, -C=O). SEM analysis has the morphological features such as spongy, fuzzy and fluffy porous network on surfaces. These results of hydrochar can be act as an active adsorbent with further activation.

Hydroponic phytoremediation of paperboard mill wastewater by using vetiver (Chrysopogon zizanioides)

Floating hydroponic system (FHS) is a potential and cost-effective technique for wastewater treatment. Vetiver (Chrysopogon zizanioides) is a more efficacious material for phytoremediation due to its physiological and morphological properties. A pilot-scale investigation on phytoremediation potential of FHS was carried out using Vetiver grass (Chrysopogon zizanioides) along with aeration on treated (TE) and raw effluents (RE) from paper board mill industry. Among the treatments, the vetiver hydroponic system with aeration had the highest treatment efficiency in the remediation of treated paper board mill effluent. The outcomes of the study exhibited a significant reduction in electrical conductivity (39.39%), total soluble salts (81.19%), and total dissolved solids (56.19%). The decline in Biological oxygen demand (55.68%) and chemical oxygen demand (58.01%) was evident at the end of the study period. The decrease in nutrients like total nitrogen (59.24%), phosphorus (47.78%), potassium (54.64%) was attributed to the growth of the vetiver grass. The lead concentration was dropped by 65.63% to 0.09 mg L−1 under the regime's permissible limits, and cadmium concentration decreased by 64.29%. From these results, the hydroponically grown vetiver treatment system combined with aeration poses a promising future for developing a sustainable, cost-effective methodology for pollutant detoxification in paperboard mill wastewater.

Effect of fertigation through treated paperboard mill effluent on soil microbial properties and growth of banana

A field experiment was conducted at agricultural farm belonging to ITC paperboard mill situated at Thekkampatty Village, Coimbatore District to evaluate the influence of fertigation through treated board mill effluent on microbial property of soil and the growth of banana. From the study it was observed that biometric observations viz., the plant height, pseudostem girth, number of leaves, number of suckers and leaf area increased due to fertigation of effluent with 75 per cent NK over basin application of the effluent and farmer’s practice. Combined addition of fly ash + biocompost + green manure recorded more number of leaves. Application of green manure along with fly ash and biocompost under effluent fertigation with 75 per cent NK improved, soil biological properties (soil bacterial, fungal, actinomycetes population and soil enzymatic activity (urease, amylase, phosphatase, invertase, catalase, peroxide activity). The above findings indicated that the treated effluent from paperboard mill could possibly be used through drip irrigation along with fertigation to banana crop without any adverse effect on soil properties and crop growth.

Benchmarking of scaling and fouling of reverse osmosis membranes in a power generation plant of paper and board mill: an industrial case of a paper and board mill study

The present study reports the characterization of reverse osmosis (RO) technology at water treatment plant Cogen-2 in paper and Board mills, Pakistan. RO is a commonly used process to obtain de-mineralized water for high-pressure boiler operation in thermal power plants. Scaling and fouling in three-stage RO plants is a major challenge in chemical industry due to the use of raw brackish water in the power plant of paper and board mills. In our study, the feed water quality of RO was changed from soft water to raw water to make it economical. The cleaning frequency was increased three times than normal, which was unsafe for operation and it was required to control scaling and fouling to achieve the desired result. Differential pressures behavior of all stages for 2-month data was observed without acid treatment, and the results of Langelier Saturation Index (LSI) control parameters (temperature, pH, total dissolved solids, calcium hardness, and alkalinity) clearly showed the abnormality. To optimize scaling and fouling of RO, the LSI factor was controlled in total reject water for the next 2 months by acid treatment in feed water. Duration of chemical cleaning and membranes’ life has been extended by fouling and scaling control. Understanding the effect of operational parameters in RO membranes is essential in water process engineering due to its broad applications in drinking water, sanitation, seawater, desalination process, wastewater treatment, and boiler feed water operation. The product flow increased from 18.3 to 19.9 m3/h, and this was due to a decrease in the rejection flow from 8.2 to 6.7 m3/h. The total reject stream pressure also increased from 8.1 to 9 bar. A lower value of LSI of 1.6 is obtained in the reject water stream after the acid treatment.

Heavy Metal Enrichment of Soil Irrigated with Paper and Board Mill (PBM) Effluents

Heavy Metal Enrichment of Soil Irrigated with Paper and Board Mill (PBM) Effluents

Preparation and Characterization of Optimized Hydrochar from Paper Board Mill Sludge

The amount of Paper Board Mill Effluent Treatment Plant Sludge (PBM-ETPS) dumped from paper mills are huge and its conversion into hydrochar for the purpose of energy has broad prospects. This study investigated the optimum conditions for the production of PBM-ETPS derived hydrochar (PBM-ETPSH) through Reponse Surface Methodology (RSM) for more surface area and pore volume with minimal hydrogen to carbon (H/C) and oxygen to carbon (O/C) ratios. The PBM-ETPSH had higher heating value (HHV) of 18.39 MJ kg−1 with fixed carbon percentage of 15.6. Our results showed a reduction in H/C (35.05%) and O/C (43.7%) ratios confirming the coalification of optimized PBM-ETPSH. Thermogravimetric investigations of blending PBM-ETPSH with coal in 1:1 ratio increased its HHV to 22.25 MJ kg−1 making it suitable as an energy alternative for paper mills.

Treatment of Pulp and Paper Industrial Effluent Using Physicochemical Process for Recycling

Physicochemical treatment, consisting of a combination of primary settling, coagulation–flocculation-aided clarification (alum, lime and magnesium sulfate as coagulants) and activated carbon adsorption, was employed for the treatment of pulp and paper mill wastewater. Treatability studies were undertaken to assess the feasibility of recycling the effluents from a paper mill. The results of laboratory scale investigation showed that the hydraulic retention time (HRT) of four hours for plain settling was effective to reduce 30% of the pollution load from pulp and board mill wastewater (PBMWW). The chemical secondary treatment reduced turbidity (89%), Chemical Oxygen Demand (84%), total suspended solids (90%) and color (89%) at the mass loading of 3400 mg/L of magnesium sulfate (MgSO4), when primary-treated effluent was subsequently treated by the coagulation–flocculation process. The combination of primary settling and lime coagulation (optimum dosage of 1400 mg/L) resulted in a turbidity removal of 94%, a COD (Chemical Oxygen Demand) reduction of 86%, a Total Suspended Solids (TSS) removal of 93% and color removal of 91.6% at an initial pH of 11. The combination of this primary settling and coagulation–flocculation treatment trial indicated that the pollutant reduction efficiency of alum was better than the other two coagulants (MgSO4, lime), because the plain settling and coagulation–flocculation process with alum (optimum dosage of 1200 mg/L) resulted in a turbidity removal of 98%, COD reduction of 93%, TSS removal of 98% and color removal of 96% at the pH 6.0 with the sludge volume index of 156 mg/L. This chemically-treated water required further treatment with activated carbon in a batch reactor for up to four hours to meet the paper mill water quality standards. Pollutant reductions at the rate of 99.5%, 99.1%, 99.4% and 99.5% were obtained for turbidity, COD, TSS and color, respectively, with the combination of the sedimentation, coagulation–flocculation process and activated carbon adsorption meeting the production process quality standards. The study revealed that a hybrid end-of-pipe physicochemical treatment was effective in reducing the pollutant load of paper mills effluent and meeting the discharging standards.

Novel methods for monitoring the sludge dewatering operation of a belt filter: a mill study

Abstract During recent decades the quality of pulp and paper mill sludge has changed. This has awakened the need for an applicable means to observe the sludge dewatering process diversely and accurately. To maximize the solids content and energy efficiency of board mill sludge dewatering, different process monitoring options were studied. Novel methods for monitoring the sludge dewatering operation of a belt filter were tested. Continuous run-time measurements and test response experiments were carried out at a board mill site. IR transmittance measurement through the filter web and sludge mat thickness measurement using a light curtain turned out to be very promising techniques. IR transmittance responded to the polymer content of the sludge without a notable time lag, while the solid content measurement of the filtrate did not give a measurable response.

Untapped volume of surplus forest growth as feedstock for bioenergy

In Canada, the annual allowable cut (AAC) sets the harvest limit of roundwood and aims to maintain the long-term productive capacity of the forest while taking into account other values such as biodiversity and needs of stakeholders. Current harvest levels in the province of Quebec, which feed an industrial network dominated by the production of lumber, panels and pulp, average only 55% of the AAC, which may cause a gradual depletion of the forest resource if stands that have the highest value are preferably selected. In this context, using surplus forest growth consisting of low quality trees and less desirable stands as bioenergy feedstock could help improve both silvicultural practices and wood value chain profitability. The aim of this study was to identify biophysical and socio-economic factors that affect the proportion of the AAC that is harvested in Quebec's 74 management units. Results from the analysis of AAC and harvesting data for the period 2008–2013 showed the harvested proportion of the AAC was particularly low for hardwood species, with the proportions for poplar, birch and maple ranging between 19 and 38%. The distance to the nearest pulp or particle board mill was confirmed as the prime factor determining the harvest/AAC ratio for deciduous species. For softwoods, the presence of deciduous stands in a given region affected the harvest/AAC ratio. Low quality hardwoods could be used as an important source of feedstock for the bioenergy sector. Developing a synergy between conventional and bioenergy products could facilitate the application of sound silvicultural practices and increase profitability along the entire wood value chain.

Evaluation of the utilization potential of debarking residue based on the requirements of Finnish waste legislation

The utilization aspects of debarking residue originating from the debarking of roundwood at an integrated pulp and board mill complex were investigated from the point of view of utilization under Finnish legislation. In Finland, the landfill deposition of organic material was restricted in 2016. The very high total organic carbon value of 385 g kg−1 (d.w.) and the loss on ignition value of 91.0% (d.w.) of the studied debarking residue both exceeded the limit value of 10% for organic materials allowed to landfill at a conventional landfill in Finland. Therefore, this residue is not allowed to be sent for landfill disposal. Due to the low dry matter content of 27.5%, this residue is also uneconomic to incinerate. Therefore, other options than incineration or landfilling must be found for its management. Due to the low total heavy metal concentrations, which were lower than their current Finnish limit values for ash used as a forest fertilizer, this material is a potential industrial residue to be used, e.g. as a fertilizer or a soil amelioration agent. According to the sequential extraction procedure, heavy metals are tightly bound to the sample matrix and this supports the possible utilization of this residue. The total heavy metal concentrations in the debarking residue were lower than the current Finnish limit value for maximum allowable heavy metal concentrations for materials used as an earth construction agent. Therefore, this residue is also suitable for use for various landscaping purposes.

Characterization of primary and secondary wastewater treatment sludge from a pulp and board mill complex to evaluate the feasibility of utilization as a soil amendment agent and a fertilizer product

In this study, we have determined the main important physical and chemical properties as well as the heavy metal concentrations of the primary and secondary wastewater treatment sludge from a pulp and board mill complex located in Finland in order to evaluate the utilization of these by-products as a soil amendment agent or a fertilizer product. Easily soluble Ca, Mg, K, Na, P and S concentrations in the sludges were extracted by ammonium acetate (CH 3 COONH 4 ) and easily soluble Cu, Mn and Zn concentrations by CH 3 COONH 4 + Na 2 EDTA. For the determination of total nutrient and total heavy metal concentrations in sludges, they were digested using aqua regia (3 mL HCl + 9 mL HNO 3 ). The total heavy concentrations in the primary sludge were lower than the Finnish heavy metal limit values for fertilizer products. In the secondary sludge, all other total heavy metals than the total Cd concentration (4.8 mg/kg; d.w.) were lower than the heavy metal limit values for fertilizer products. Due to the low total heavy metal concentrations, which were lower than the Finnish limit values for fertilizer products, the primary sludge is a potential fertilizer. Although the total Cd concentration (4.8 mg/kg; d.w.) in the secondary sludge exceed the limit value of 1.5 mg/kg (d.w.) for fertilizer products, this residue may be used as a soil improver, a growing media or as a fertilizer product in landfill sites or in other closed industrial areas, because the Finnish limit values for fertilizer products are not applied at these sites.

Process water properties from hydrothermal carbonization of chemical sludge from a pulp and board mill

Hydrothermal carbonization (HTC) can be used to break down sludge structure and generate carbonaceous hydrochar suitable for solid fuel or value-added material applications. The separation of char and the reaction medium however generates a filtrate, which needs to treated before potential discharge. Thus, this work determined filtrate properties based on HTC temperature and sludge moisture content and estimated the discharge emissions and the potential increase in analyte loads to an industrial wastewater treatment plant based on derived regression models. Direct discharge of HTC filtrate would significantly increase effluent emissions at the mill, indicating the filtrate treatment is crucial for the future implementation of HTC at pulp and paper mills. Recycling the HTC filtrate to the wastewater plant would lead to only a nominal increase in effluent flow, but would increase the suspended solids, BOD, COD and total nitrogen loads by 0.1–0.8%, 3.8–5.3%, 2.7–3.1% and 42–67%, respectively, depending on HTC temperature.

SAKARIFIKASI LUMPUR PRIMER INDUSTRI KERTAS SECARA FED BATCH MENJADI GLUKOSA UNTUK PEMBUATAN BIOETANOL (FED BATCH SACCHARIFICATION OF PRIMARY PAPER MILL SLUDGE TO PRODUCE FERMENTABLE SUGAR)

Research of fed batch saccharification using paper mill primary sludge from Waste Water Treatment Plant (WWTP) has been conducted. The research was conducted in several stages i.e. sludge characterization, determining optimum dosage of cellulase and glucosidase through batch saccharification, and continued with fed batch saccharification. The characterization was performed on 3 primary sludge type from 3 paper mill, which are print paper mill with virgin pulp raw material, paper tissue mill with virgin pulp raw material and core board mill with waste paper raw material. The characterization results showed that the sludge derived from the tissue paper mill with virgin pulp raw material has the highest content of cellulose which is 47.06%, this sludge was used as further research material. The initial trial of batch saccharification at 6% w/w and temperature of 60oC gave optimum dosage of cellulase 9 FPU/g cellulose and β-glucosidase 80 IU/g cellulose with reducing sugar 20.01 g/L and a saccharification efficiency of 63.84%. Fed batch saccharification was performed on tissue paper mill sludge at cellulase and glucosidase enzyme doses respectively 9 FPU/g cellulose and 80 IU/g, temperature 60°C and initial pH of 4 with two variables, which are cumulative solid content (10%, 14%, and 18% w/v) and feed enzyme system (at the beginning and in step). The best results were obtained at fed batch sakarifikasi with gradual enzyme feeding at 14% solids content resulting in reducing sugar 43.899 g/L and efficiency 60.03%.

Performance and cost of CCS in the pulp and paper industry part 2: Economic feasibility of amine-based post-combustion CO2 capture

The economic feasibility of retrofitting an amine based post-combustion CO2 capture process to an existing Kraft pulp mill and an existing integrated pulp and board mill has been assessed. This study builds on the technical assessment of the energy performance of the mills when retrofitting a post-combustion CO2 capture process by Onarheim et al. (2017).Between 75 to 100% of the CO2 emissions from the pulp and paper industry originate from the combustion of biomass. If the raw material is sourced sustainably, these emissions are categorized as carbon neutral. Applying sustainably managed biomass in the pulp and paper processes and capturing the resulting CO2 for permanent storage enables the industry to go carbon negative. In this study, the economic impact of retrofitting CO2 capture from the flue gases of the recovery boiler, the multi-fuel boiler and the lime kiln were assessed.The levelized cost of pulp and the cost of CO2 avoided were evaluated based on six different scenarios varying the CO2 tax, incentives for renewable electricity production, with and without recognizing biogenic CO2 emissions as neutral (exempting CO2 emissions from tax or not), and rewarding captured and permanently stored CO2 with negative emissions credit. Results show that the pulp and paper industry has a potential for realizing feasible implementation of large-scale industrial Bio-CCS. For cases where 60–90% of total site CO2 emissions are captured, the cost of avoided CO2 amounts to 52–66 €/t for the Kraft pulp mill and 71–89 €/t for the integrated pulp and board mill. The cost of avoided CO2, and thus the realization of Bio-CCS in the pulp and paper industry, is strongly dependent on prevailing policy frameworks such as the EU ETS. In order to reach a levelized cost of pulp similar to the reference mill without CO2 capture, a negative CO2 emission credit of 60–70 €/t CO2 for the Kraft pulp mill and 70–80 €/t CO2 for the integrated pulp and board mill will be required.As long as biogenic CO2 emissions that are captured and permanently stored are not recognized as negative and rewarded accordingly there is no economic incentive for the owners of pulp and paper mills to implement CCS. The only way to get the pulp and paper industry to implement and deploy Bio-CCS will need the support of the decision-makers in promoting the right policy framework and regulations to encourage the investment such as strong incentives for negative emissions which are bankable during the long term operation of the mills.

Performance and costs of CCS in the pulp and paper industry part 1: Performance of amine-based post-combustion CO2 capture

The performance of an amine-based post-combustion CO2 capture and storage (CCS) process in an existing Kraft pulp mill and an existing pulp and board mill was assessed. The pulp and paper industry is an energy-intensive industry, with significant amounts of CO2 emitted onsite. The majority of this CO2 originates from the combustion of biomass, which renders it carbon neutral if the biomass used by the industry is grown and harvested in a sustainable manner. If the CO2 emissions from the pulp and paper industry were to be captured and permanently stored, then this could make the industry a potential carbon sink. In this evaluation, different configurations of capturing CO2 from the flue gases of the recovery boiler, the multi-fuel boiler and the lime kiln were assessed. For a stand-alone Kraft pulp mill, the excess steam available is sufficient to cover the demand from the CO2 capture plant. For an integrated pulp and board mill, there is less excess steam available for the CO2 capture plant and an auxiliary boiler may be required. The retrofit of a post-combustion CO2 capture plant into an existing pulp mill increases the steam demand by 1–8GJ/air dried tonne (adt) pulp, depending on the volume of the flue gas treated. This translates to a reduction in the amount of electricity exported to the grid by 0.1–1.0MWh/adt pulp for a stand-alone Kraft pulp mill, and by 0.1–0.5MWh/adt pulp for an integrated pulp and board mill. The total potential for negative CO2 emissions amounts to just under 2.0 Mt CO2/a both for the market pulp mill and for the integrated pulp and board mill.

Oriented Strand Board: Opportunities and Potential Products in China

North America's first oriented strand board (OSB) mill was built in the early 1980's. Twenty years later, the industry was thriving, with over 50 mills producing the product. China's first OSB mill was built in 1990, and 25 years later, there are a few mills with a total capacity less than two large North America mills, most operating below capacity and struggling to identify domestic markets for the growing production. This paper briefly looks at the histories of OSB industries in North America and China, presents the current situation of China’s wood-based panels industry and its downstream industries, and identifies OSB opportunities and potential products in China. Opportunity for sheathing-grade OSB is very limited in the current Chinese market, whereas industrial opportunities for specialty OSB products to replace plywood have great potential. Those specialty products include materials for furniture, wood doors, wood flooring, container flooring, concrete form, etc. OSB producers must designate the right OSB products for the Chinese market and cost-effectively manufacture those differentiated products to meet specifications for various end-applications.

Oriented strand board: Opportunities and potential products in China

North America’s first oriented strand board (OSB) mill was built in the early 1980’s. Twenty years later, the industry was thriving, with over 50 mills producing the product. China’s first OSB mill was built in 1990, and 25 years later, there are a few mills with a total capacity less than two large North America mills, most operating below capacity and struggling to identify domestic markets for the growing production. This paper briefly looks at the histories of OSB industries in North America and China, presents the current situation of China’s wood-based panels industry and its downstream industries, and identifies OSB opportunities and potential products in China. Opportunity for sheathing-grade OSB is very limited in the current Chinese market, whereas industrial opportunities for specialty OSB products to replace plywood have great potential. Those specialty products include materials for furniture, wood doors, wood flooring, container flooring, concrete form, etc. OSB producers must designate the right OSB products for the Chinese market and cost-effectively manufacture those differentiated products to meet specifications for various end-applications.