TNPL- Internship Report

Submitted by

A Niranjana Anur Aruna Sasti

(CB.EN.U4CHE22001)
Abaya Pradhan Yadav
(CB.EN.U4CHE22007)

BACHELORS OF TECHNOLOGY
IN
CHEMICAL ENGINEERING
AMRITA VISHWA VIDYAPEETHAM,
AMRITA UNIVERSITY,
COIMBATORE-641112.
21ST June - 5th July ,2024.

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 ACKNOWLEDGEMENT
We would like to express our deepest gratitude to Tamil Nadu Newsprint
and Papers Limited (TNPL) -Karur ,for providing us with the invaluable
opportunity to undertake the internship as a 2nd-year BTech Chemical
Engineering student. This experience has been instrumental in enhancing
my understanding of real-world applications in the field of chemical
engineering.

We extend my heartfelt appreciation to the entire staff at TNPL-Karur for

their guidance, support, and willingness to share their knowledge
throughout our internship. Special thanks to
Mr.K.Rajanbabu.DGM(P.M/c),
Mr.Shiva Kumar.AGM(P.M.3), Mr.Santhakumar.J.AGM(Pulp),
Mr.Ravichandran.P.Chief Manager(Pulp),
Mr.Madhavan.B.Sr.Manager(Soda Recovery),
Mr.Karunanithi.P.Chief Manager(Lab),Mr.Radhakrishnan,
Mr.Soundar Rajan,Mr.Nanmugan,Mr.Karthi,Mr.Madhavan for their
mentorship, encouragement and guidance which played a significant role
in our learning journey. We are also grateful to all the employees who
took the time to engage with us, share their expertise, and answer our
queries, thereby enriching our experience and broadening our perspective
on the industry.
We also thank our university for facilitating this wonderful internship
opportunity and for their continuous support in our academic and
professional endeavors. This internship has been a truly enriching
experience, and we are confident that the lessons learned and skills
acquired will serve as a solid foundation for our future endeavors in the
field of chemical Engineering.
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 TABLE OF CONTENT
CHAPTER TITLE PAGENO.

1 INTRODUCTION 4-6
2 Safety guideline 7-11

3 Paper manufacturing overview 11 -14

4 Pulp from Hard Wood 15

4.1 Debarking & Chipping of Wood 15-18

4.2 Hard Wood Plant 19

4.2.1 Cooking of Wood chips & screening 20

4.2.2 Removal of lignin using oxygen 21

4.2.3 Bleaching and Washing 21

5 Pulp from CBP VS pulp from HWP 23 -24

6 De-inked pulp 25 -26

8 Soda Recovery Plant 27-29

9 𝐶𝑙𝑂2 Production 30-36

10 Paper Production 37 -42

11 R&D 42 -46

12 Conclusion 46 -48

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 INTRODUCTION

Importance of Paper
Paper has been a fundamental part of human civilization for centuries. Its
invention revolutionized communication, education, and administration, making
the dissemination of information and ideas more accessible and widespread.
Despite the digital age, paper remains an indispensable material in various
sectors, including education, packaging, and sanitation. The tactile nature of
paper and its recyclability also contribute to its sustained relevance in a world
increasingly conscious of environmental sustainability.

About TNPL Karur

Tamil Nadu Newsprint and Papers Limited (TNPL) is a prominent name in the Indian paper
industry, known for its innovation, sustainability, and commitment to excellence. Established
in 1979, TNPL has grown to become one of the largest producers of paper in India, with a
state-of-the-art manufacturing facility located in Karur, Tamil Nadu. The Karur facility is
renowned for its advanced production processes and sustainable practices, making it a leader
in the industry.

TNPL: Pioneering Sustainable Practices

NPL has consistently pursued environmentally friendly practices and has been a pioneer in
the use of bagasse for paper production. The company has developed an integrated
manufacturing process that converts bagasse into high-quality paper, reducing its reliance on
wood and minimizing environmental impact.

TNPL's approach to sustainability extends beyond raw material usage. The company has
implemented advanced waste management systems, water recycling, and energy-efficient
technologies in its production processes. These initiatives have significantly reduced TNPL's
carbon footprint and have set benchmarks for the industry.

Evolution and Developments

Since its inception, TNPL has undergone significant developments and expansions to
enhance its production capabilities and environmental sustainability. Initially focused on
using hardwood as the primary raw material, TNPL soon recognized the environmental
impact and challenges associated with this resource. In response, the company pioneered the
use of bagasse, a byproduct of sugarcane processing, as an alternative raw material. This shift

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not only reduced the dependency on wood but also promoted the utilization of agricultural
waste, aligning with global sustainability goals.

Over the years, TNPL has continuously upgraded its technology and infrastructure. The
Karur plant has been equipped with state-of-the-art machinery and advanced production
techniques to ensure high-quality paper production. The adoption of modern pulping and
bleaching processes has enhanced the efficiency and consistency of the final product.
Additionally, TNPL has invested in research and development to innovate and improve its
production methods.

Future Scope of Paper

The future of the paper industry lies in diversification and innovation. There is a growing
market for eco-friendly and recyclable paper products as consumers become more
environmentally conscious. Advances in technology are enabling the development of high-
quality, specialized papers for various applications, from packaging to medical uses.
Furthermore, the industry is exploring alternative raw materials such as agricultural residues
and recycled fibers to reduce environmental impact and ensure sustainability.

TNPL continues to explore new frontiers in paper production. The company's research and
development efforts focus on enhancing the quality of bagasse-based paper, developing new
product lines, and further improving environmental performance. By leveraging cutting-edge
technologies and maintaining a strong commitment to sustainability, TNPL aims to remain a
leader in the global paper industry and contribute to a greener future.

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 Safety guidelines at TNPL

Safety guidelines at TNPL (Tamil Nadu Newsprint and Papers Limited) are
designed to ensure the safety and well-being of all employees, contractors, and
visitors. These guidelines cover various aspects of workplace safety, including
equipment handling, personal protective equipment (PPE), emergency
procedures, and general workplace conduct. The key safety guidelines typically
followed at TNPL are :

General Safety Guidelines

1. Safety Induction: All new employees, contractors, and visitors must
undergo safety induction training before entering the production areas.
2. Awareness and Training: Regular safety training sessions and
awareness programs should be conducted for all employees to keep them
informed about potential hazards and safe work practices.
3. Safety Signage: Clear and visible safety signs should be posted
throughout the facility to indicate hazards, emergency exits, and safety
equipment locations.

Personal Protective Equipment (PPE)

1. Mandatory PPE: Employees must wear appropriate PPE, including
helmets, safety glasses, gloves, ear protection, and safety shoes, in
designated areas.
2. Specialized PPE: Additional PPE such as respiratory protection,
chemical-resistant clothing, and face shields must be used when handling
hazardous materials or working in specific areas.

Equipment and Machinery Safety

1. Machine Guarding: All machinery must be equipped with proper guards and safety
interlocks to prevent accidental contact with moving parts.
2. Lockout/Tagout (LOTO): Implement and follow LOTO procedures during maintenance and
repair work to ensure machines are properly shut off and cannot be accidentally started.
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 3. Inspection and Maintenance: Regular inspection and maintenance of equipment and
machinery to ensure they are in safe working condition.

Chemical and Hazardous Material Handling

1. Material Safety Data Sheets (MSDS): Maintain and make accessible
MSDS for all chemicals used in the facility.
2. Proper Storage: Store chemicals and hazardous materials in designated
areas with appropriate labeling and containment measures.
3. Spill Response: Equip the facility with spill response kits and train
employees on how to respond to chemical spills and leaks.

Fire Safety
1. Fire Extinguishers: Place fire extinguishers in accessible locations and
ensure they are regularly inspected and maintained.
2. Fire Drills: Conduct regular fire drills to ensure all employees are
familiar with evacuation procedures.
3. Emergency Exits: Keep emergency exits clear and ensure they are
clearly marked and easily accessible.

The 5S Rule in TNPL

The 5S methodology is a systematic approach to workplace organization and
standardization, originating from Japan and commonly associated with lean
manufacturing and continuous improvement. The 5S's stand for:

1. Sort (Seiri)
2. Set in Order (Seiton)
3. Shine (Seiso)
4. Standardize (Seiketsu)
5. Sustain (Shitsuke)

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Detailed Explanation of Each S:

1.Sort (Seiri):-

⚫ Objective: Eliminate unnecessary items from the workplace.

⚫ Action: Evaluate each item in a work area and keep only what is
essential. Remove or dispose of anything that is not needed.
⚫ Outcome: Reduced clutter, freeing up space and improving workflow.

2.Set in Order (Seiton)

⚫ Objective: Organize the necessary items so they are easy to find and
use.
⚫ Action: Arrange tools, equipment, and materials in a logical manner so
that they are easily accessible. Label storage areas and create clear
signage.
⚫ Outcome: Increased efficiency and reduced time spent searching for
items.

3.Shine (Seiso)

⚫ Objective: Clean the workspace and maintain its cleanliness.

⚫ Action: Regularly clean the work area and equipment. Inspect the area
during cleaning to identify potential issues.
⚫ Outcome: A clean and tidy workplace that is safer and more pleasant,
and the identification of potential maintenance issues early on.

4.Standardize (Seiketsu)

⚫ Objective: Establish standards and routines to maintain the first three

S's.
⚫ Action: Develop procedures and schedules for sorting, organizing, and
cleaning. Standardize best practices and ensure everyone follows them.
⚫ Outcome: Consistent application of 5S principles across the
organization, leading to sustained improvements.

5.Sustain (Shitsuke)

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 ⚫ Objective: Embed the 5S methodology into the culture of the
organization.
⚫ Action: Train employees, conduct regular audits, and encourage
continuous improvement. Reinforce the importance of following 5S
practices through leadership and example.
⚫ Outcome: Long-term maintenance of the organized, clean, and efficient
workspace, leading to ongoing benefits.

Benefits of Implementing 5S:

⚫ Improved Productivity: By organizing and streamlining the workspace,

employees can work more efficiently.
⚫ Enhanced Safety: A clean and organized work environment reduces the
risk of accidents and injuries.
⚫ Reduced Waste: By eliminating unnecessary items and optimizing
storage, waste is minimized.
⚫ Higher Quality: Standardized processes lead to more consistent quality
in products and services.
⚫ Employee Satisfaction: A well-organized and clean workplace can
boost morale and job satisfaction.

The 5S methodology is a foundational element of lean manufacturing and can be

adapted to various industries and work environments, including office settings,
manufacturing plants, and service industries.

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 Paper Production Overview

The paper production process is a complex and meticulously planned sequence of operations
that transform raw materials into finished paper products . The paper making process starts
from the acquisition of raw materials such as hardwood, bagasse, and deinked pulp . The
process begins with the conversion of hardwood and bagasse into pulp through mechanical
and chemical treatments, ensuring the efficient use of each material. Bagasse undergoes
classification and depithing to prepare it for pulping, while hardwood is chipped and
processed in dedicated plants. The integration of deinked pulp underscores the commitment
to recycling and sustainability within the industry. Additionally, the diagram highlights the
recycling of edge trimmings, which are ground into pulp slurry and reintroduced into the
production stream, thereby minimizing waste. The mixed pulp stream is then processed in
paper machines, where fillers and additives are incorporated to enhance the quality of the
final product. The finishing stages include reeling, packaging, and shipping, completing the
journey from raw material to ready-for-use paper.

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Start:

• The process begins with three primary raw materials: hardwood, bagasse,
and deinked pulp.

Hardwood:

• Hardwood: This raw material undergoes chipping to produce wood

chips.

• Chips for Pulp: The wood chips are processed into pulp at the HW
(Hardwood) Plant.
• Weak Black Liquor (WBL): A byproduct of the pulping process, weak
black liquor is sent to the SRP (Soda Recovery Process) for further
processing.

Bagasse:

• Bagasse: A byproduct of sugarcane processing.

• Bagasse (Classified): Bagasse is classified to ensure quality before

entering the depither.
• Depither: Removes pith from the bagasse to prepare it for pulping.
• Bagasse Yard (Storage): the DE-pithed Bagasse is stored in the yard for
handling and further processing.
• Bagasse Handling: The stored bagasse is prepared for pulping.
• Bagasse chips are processed into pulp at the CBP (Chemical Bagasse
Pulping) Plant.
• Weak Black Liquor (WBL): Similar to the HW plant, the weak black
liquor byproduct is sent to the SRP for processing.

SRP (Soda Recovery Process):-

⚫ Processes the weak black liquor into white liquor, which is reused in
the HW and CBP plants.

Deinked Pulp:

⚫ Deinked Pulp: Directly enters the mixed pulp stream, contributing to

the paper production process. Of around %
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Mixed Pulp Stream:

• The mixed pulp stream combines hardwood pulp, bagasse pulp, and
deinked pulp. This mixture is essential for paper production.

Paper Machine:

• The mixed pulp stream enters the paper machine, where it is processed
into paper.

• Fillers and Additives: These materials are added to the pulp to improve
the quality and characteristics of the final paper product.

Edge Trim Recycling:

• Edge (for trimming of paper): The edges of the produced paper are
trimmed and sent to a grinder.
• Grinder: The trimmings are ground into pulp slurry and reintroduced
into the mixed pulp stream.

Finishing, Reeling, Packaging, and Shipping:

• The finished paper is reeled, packaged, and prepared for shipping.

End:

• The final step of the paper production process, where the finished product
is ready for distribution.

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Pulp From Hard Wood
Debarking & Chipping of Wood:

The process of converting eucalyptus and casuarina wood from plantations into
wood chips is a critical operation in the paper production industry. This flow
sheet outlines the comprehensive steps involved in transforming raw wood logs
into uniformly sized wood chips, ready for use in the HW (Hardwood) plant.
The process begins with debarking, where the bark is removed from the logs.
The debarked logs are then processed through different types of chippers: disc
chippers and drum chippers. The disc chippers, each equipped with multiple
blades, produce approximately 120 tonnes of wood chips, while the drum
chipper, fitted with a larger number of blades, produces around 30 tonnes of
wood chips per hour. The wood chips from the disc chippers are screened using
a vibrating screen to ensure they meet the 7mm size specification, while the
chips from the drum chipper pass through an oscillating screen. Oversized chips
from both chippers are redirected to rechippers for resizing. The correctly sized
wood chips are then stored in silos before being transferred to the HW plant for
further processing. This meticulous process ensures a steady supply of high-
quality wood chips, optimizing raw material use and enhancing production
efficiency.

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Eucalyptus & Casuarina Wood from Plantation:

The process begins with the procurement of eucalyptus and casuarina

wood logs from plantations.

Debarking:

The wood logs undergo debarking to remove the bark, ensuring that
only the wood is processed further.

Chipping:

The debarked wood is then directed to different chippers:

Disc Chipper 1 and Disc Chipper 2:

These chippers produce wood chips from the logs.

Production Data:

The Disc chippers both collectively produce approximately 120

tonnes of wood chips per day.

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Drum Chipper:

Another type of chipper used to produce wood chips.

Production Data:

The drum chipper alone produces around 30 tonnes of wood chips

per hour.

Screening:

The chips produced by the chippers are then screened for size.

Screen for 7.5mm Chips:

Chips are screened to ensure they meet the 7.5mm size

specification.

Drum Screen for 7.5mm:

Similar screening process for chips from the drum chipper.Chips

that do not meet the size requirement are sent to the rechipper for resizing.

Re-chipper:

Oversized chips are processed in the rechipper to achieve the desired

size of 7.5mm.

Wood Chips:

The correctly sized wood chips are collected and stored in silos.

Silos:

The silos store the wood chips until they are needed for further
processing in the HW plant.

To HW Plant:

The final step involves transferring the wood chips from the silos to
the HW plant, where they will be used in the pulping process.

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Summary of Production Data
• Disc Chippers:

Each produces approximately 120 tonnes of wood chips a day.

o
• Drum Chipper:

o Produces around 30 tonnes of wood chips per hour.

This efficient chipping and screening process ensures a consistent supply of

high-quality wood chips for the HW plant, optimizing the use of raw materials
and enhancing overall production efficiency.

Disc Chipper Mechanism: Disc chippers operate by feeding logs into a

rotating disc equipped with multiple blades. As the disc spins, the blades slice
the wood into chips. Typically, disc chippers used in this process have several
blades mounted radially on the disc. The chips produced by disc chippers pass
through a vibrating screen to ensure they meet the 7.5mm size specification.
Any oversized chips are redirected to rechippers for resizing. The disc chippers
in this flow sheet produce approximately 120 tonnes of wood chips each.

Drum Chipper Mechanism: Drum chippers function by feeding wood into a

large rotating drum that is fitted with numerous blades along its circumference.
As the drum rotates, the blades cut the wood into chips. This design allows for
high-capacity chipping, with the drum chipper in this process producing around
420 tonnes of wood chips. The chips from the drum chipper pass through an
oscillating screen to ensure they meet the desired size requirement. Oversized
chips are also sent to rechippers for resizing.

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 Hard Wood Pulp

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Importance and Necessity of Pulp from Hardwood
The pulp obtained from hardwoods, particularly from eucalyptus and Casuarina
trees, plays a crucial role in the paper manufacturing industry. Hardwood pulp is
renowned for its short fibers, which contribute to the smoothness, opacity, and
printability of paper. This makes it indispensable for producing high-quality
printing and writing papers, tissue papers, and specialty papers. The Kraft
process, used to extract pulp from hardwood, ensures a strong and durable fiber,
making it suitable for a wide range of paper products. With the growing demand
for sustainable and eco-friendly paper, hardwood pulp, derived from sources
like eucalyptus and Casuarina, has become essential in meeting both
environmental standards and market needs.

Hardwood Pulping Using the Kraft Process

The digester that we use in TNPL Hard wood pulp making is Super Batch
Digester.We are using 3 different batch digesters simultaneously by adjusting
streams which make the process alike a continuous digester operation.

1. Wood Chips from Silos:

o Hardwood chips from eucalyptus(inner part white in colour) and
Casuarina trees(inner part red in colour) are sourced from silos.
2. Digester:
o The wood chips are fed into a digester, where they are cooked with
steam, white liquor, and black liquor to break down the lignin and
separate the cellulose fibers.Here in TNPL the digestion process in
done in 4 stages namely:-1)Chip Stacking/Chip filling and
Impregnation,2)Cooking,3)Displacement,4)Pump Discharge.
3. Discharge to Tank:
o The cooked wood chips are discharged into a tank to cool down
and prepare for further processing by overflowing the cooked
liquor in the digester with cool white liquor +wood chips from the
bottom.
4. Screening:
o The pulp is screened to remove any remaining wood chips and
other impurities.
5. Washing Press:
o The screened pulp is washed to remove cooking chemicals and
other residues.
6. Oxygen Reactor:

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 The washed pulp is treated in an oxygen reactor with oxidizing
o
white liquor, oxygen, and steam to further bleach the pulp. The
initial brightness of the pulp is greater than 30%.
7. Blow Tank:
o The pulp is blown into a tank for mixing and homogenization.
8. O2 Press:
o The pulp undergoes pressing to remove excess water. Post O2
press, the pulp brightness increases to over 45%.
9. DHt Reaction Tower:
o The pulp is treated in the DHt reaction tower with chlorine dioxide,
steam, and sulfuric acid (H2SO4). This stage significantly
increases the pulp brightness to over 65%.
10.DHt Tower:
o The pulp is further processed in the DHt tower to stabilize the
bleaching.
11.EOP Reaction Tower:
o The pulp undergoes treatment with caustic, oxygen, and peroxide
in the EOP (Extraction with Oxygen and Peroxide) reaction tower.
This process enhances the brightness to over 78%.
12.EOP Press:
o The pulp is pressed again to remove excess water and prepare for
final bleaching stages.
13.D1 Reaction Tower:
o The pulp is treated with chlorine dioxide (ClO2) and sulfuric acid
(H2SO4) in the D1 reaction tower to achieve a higher level of
brightness.
14.D1 Press:
o The pulp is pressed one last time, reaching a final brightness of
around 85%-87%.
15.Storage Tower:
o The fully bleached pulp is stored in a tower, awaiting further
processing.
16.To Paper Machine:
o The high-brightness pulp is then sent to the paper machine to be
formed into paper products.

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Differences in Using Bagasse Instead of Hardwood
for Paper Production via Kraft Process
1. Source and Availability:
o Hardwood: Sourced from trees like eucalyptus and Casuarina,
requiring forestry and longer growth cycles.
o Bagasse: A byproduct of the sugarcane industry, making it readily
available and renewable with each sugarcane harvest cycle.
2. Fiber Characteristics:
o Hardwood: Contains short fibers, providing smoothness, opacity,
and good printability to paper. The fiber structure is strong and
durable.
o Bagasse: Contains a mix of short and medium fibers, which can
impart different properties to paper, such as a slightly softer texture
and less smoothness compared to hardwood pulp.
3. Environmental Impact:
o Hardwood: Requires significant land use and long-term forestry
management. It has a larger ecological footprint due to
deforestation concerns and longer regeneration times.
o Bagasse: Utilizes agricultural waste, reducing the environmental
impact by promoting waste recycling. It helps in minimizing waste
disposal problems in the sugarcane industry.
4. Chemical Composition:
o Hardwood: Higher lignin content, requiring more intense
chemical treatment during the Kraft process to break down the
lignin and release the cellulose fibers.
o Bagasse: Lower lignin content, making it easier and more efficient
to process. This results in reduced chemical usage and energy
consumption during the pulping process.
5. Processing Efficiency & depithing:
o Hardwood: The pulping process is well-established with
predictable outcomes, but it requires more chemicals and energy
due to higher lignin content.
o Bagasse: Easier to process due to lower lignin content, resulting in
higher pulping yields and lower chemical and energy requirements
and requires to be depithed.
6. End Product Quality:
o Hardwood: Produces high-quality paper with superior smoothness
and printability, suitable for premium printing and writing papers.
o Bagasse: Produces paper with good strength and acceptable
printability, but may not achieve the same level of smoothness and
brightness as hardwood pulp.
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 7. Economic Considerations:
o Hardwood: Involves higher costs related to forestry management,
longer growth periods, and more intensive processing.
o Bagasse: More cost-effective due to its status as a byproduct of the
sugarcane industry, reducing raw material costs and leveraging
existing supply chains.
8. Sustainability:
o Hardwood: Sustainable forestry practices are essential to mitigate
environmental impact, but the long growth cycles pose challenges.
o Bagasse: Promotes circular economy principles by using
agricultural waste, contributing to sustainability and reducing the
overall carbon footprint.

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Introduction to Deinked Pulp (DIP) and Rotary Kiln
Processing:
Deinked Pulp (DIP) is an essential component in the recycling process of paper,
aiming to reclaim fibres from used paper and convert them into high-quality
pulp suitable for producing new paper products. The deinking process involves
various mechanical and chemical treatments to remove contaminants such as
ink, dyes, and ash, enhancing the brightness and cleanliness of the recycled
fibres. A crucial apparatus in this process is the rotary kiln, which plays a
pivotal role in efficiently separating usable fibres from impurities

The rotary kiln is divided into two primary zones: the slusher zone and the
filtering zone. In the slusher zone, the paper material is broken down into a
pulp slurry, which consists of fibers and contaminants. This initial treatment
helps in disintegrating the paper and liberating the ink particles. The pulp then
moves to the filtering zone, where it passes through screens with holes of
varying sizes—9mm, 8mm, and 7mm. Fibers that meet the size criteria fall into
the vat, while oversized contaminants are rejected. The pulp slurry collected in
the vat contains a mixture of fiber and residual contaminants, including ash,
dyes, and ink, with an initial brightness of around 60%.

This staged separation ensures that only fibers of the desired size proceed
further in the deinking process, optimizing the quality and efficiency of the
recycling operation. The rotary kiln's design and function are critical in
achieving the high standards required for producing recycled paper, contributing
to the sustainable management of paper resources.

➢ Pulping:
Chemicals added: Sodium Silicate (Na2SiO3), Sodium Hydroxide
(NaOH), Hydrogen Peroxide (H2O2), Surfactant, and Na-Soap.
➢ HD Cleaning (2 Stages):
Removes heavy contaminants.
➢ Coarse Screening (3 Stages):
Screens out larger impurities such as plastic.
➢ MC Screening (3 Stages):
Further screening of medium-sized contaminants.
➢ 1st Flotation:
Removes ink, gum, and egg residues using Na-soap. The accepts proceed
to further processing, and the rejects go to sludge handling.
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 ➢ Dispersing 1:
The pulp is dispersed to crush fibres and increase brightness by 10%.
➢ Thickening 1:
Pulp consistency increased to 12%.
➢ Fine Screening (2 Stages):
Screens fine contaminants. Some rejects are sent to sludge handling.
➢ LC Cleaners (4 Stages):
Cleaners remove sand and other fine particles. Accepts move forward in
the process, and rejects are sent to sludge handling.
➢ NaOH, H2O2 Treatment:
Pulp is treated with Sodium Hydroxide and Hydrogen Peroxide to further
increase brightness.
➢ Dispersing 2:
Further dispersal of pulp. Brightness increases to 68%.
➢ Thickening 2:
Pulp consistency increased again.
➢ 2nd Flotation:
Further deinking with Na-soap, surfactant, and surfactant, with rejects
going to sludge handling.
➢ Bleach Tower:
Pulp is bleached with H2O2 to achieve higher brightness (75%).
➢ Thickening 3:
Pulp is thickened and further treated with steam.
➢ 3rd Flotation:
Final flotation to remove remaining ink, treated with Na-soap and
surfactant.
➢ Bleach Tube:
Final bleaching stage using Na2S2O4 for 1 hour to achieve a brightness
of around 83%-84%.
➢ Storage Tower:
The fully processed and bleached pulp is stored, ready for further paper
manufacturing.

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 SRP:

Introduction to Soda Recovery Process in Pulp Mills

The soda recovery process in pulp mills is a crucial aspect of sustainable paper production. It
involves the recovery and recycling of chemicals used in the pulping process, thereby
reducing waste and minimizing environmental impact. The primary objective is to reclaim
chemicals like sodium hydroxide and sodium carbonate from the spent black liquor,
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converting them back into reusable form. This process not only enhances the efficiency of the
pulping operation but also significantly reduces the cost associated with purchasing fresh
chemicals. The flow chart illustrates the detailed steps involved in a soda recovery plant,
ensuring a continuous and efficient recycling loop.

Soda Recovery Plant In TNPL

1. Pulp Mill:
o The process starts at the pulp mill where black liquor is generated
as a byproduct of the pulping process.
2. HW WBL Storage:
o The black liquor is first collected in the HW (Hardwood) WBL
(Weak Black Liquor) storage tanks.
3. CBP WBL Storage:
o Similarly, CBP (Chemical Black Pulper) WBL is stored after
passing through vibro-screens to remove impurities.
4. Falling Film Evaporator (C Stream and D Stream):
o The weak black liquor from storage tanks is concentrated using
falling film evaporators. The C stream and D stream evaporators
reduce the water content, increasing the solids concentration.
5. SCBL Tank:
o The concentrated black liquor (Strong Black Liquor) is then stored
in the SCBL tank.
6. Recovery Boilers (II and III):
o The strong black liquor is combusted in recovery boilers. These
boilers recover energy and produce smelt, which contains sodium
carbonate and sodium sulfide.
7. HBL Tank and MDT:
o The smelt is dissolved in water to form green liquor, which is then
processed in the HBL (Heavy Black Liquor) tank and MDT
(Multiple Dissolving Tank).
8. Weak White Liquor Storage:
o The green liquor is converted into weak white liquor through a
series of reactions. This weak white liquor is stored for further
processing.
9. Homogenization Tank:
o The weak white liquor is homogenized to ensure uniformity before
further chemical treatment.
10.First Stage Slaking & Causticizing:
o Lime is added to the weak white liquor in the first stage slaking
and causticizing unit to convert sodium carbonate into sodium
hydroxide, forming white liquor.
11.Green Liquor Clarification:
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 The green liquor is clarified to remove impurities and ensure high-
o
quality white liquor production.
12.Clarified Green Liquor Storage:
o The clarified green liquor is stored for use in the causticizing
process.
13.Second Stage Slaking & Causticizing:
o The process continues with a second stage of slaking and
causticizing to ensure complete conversion of sodium carbonate.
14.White Liquor Clarification & WLCD Filter:
o The white liquor is clarified and filtered to remove any remaining
impurities, producing high-purity white liquor.
15.White Liquor Storage:
o The purified white liquor is stored for reuse in the pulping process.
16.Mud Washing (First and Second Stage):
o Lime mud, a byproduct of the causticizing process, is washed in
multiple stages to recover any residual chemicals.
17.First and Second Stage Filters:
o The washed lime mud is filtered to separate solids from the liquid.
18.Lime Mud Re-Burning Kiln:
o The lime mud is calcined in a kiln to regenerate lime, which is then
recycled back into the causticizing process.
19.Lime Stone Addition:
o Limestone is added to the homogenization tank to aid in the
causticizing reactions.
20.Mud Tank and LSFM Plant:
o Finally, the remaining mud is stored in a mud tank before being
processed in the LSFM (Lime Sludge Fuel Mix) plant.

Lime Klin: In TNPL at present we use 2 Lime Klins which combinedly produce
170 Ton CaO Per Day.

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 𝐂𝐥𝐎𝟐 𝐏𝐫𝐨𝐝𝐮𝐜𝐭𝐢𝐨𝐧:

Introduction to ClO₂ Production Process at TNPL

The production of Chlorine Dioxide (ClO₂) at TNPL is a very crucial
component which acts as a bleaching agent which helps to reduce the lignin
content and improve its brightness. It is produced by combines various chemical
reactions and mechanical processes. The primary raw materials include brine
solution (NaCl), strong chlorate (NaClO₃), and hydrogen chloride (HCl). The
process flows through multiple stages, including electrolysis, scrubbing,
cooling, and absorption to produce ClO₂ efficiently and safely. The following
detailed description outlines the various stages and equipment involved in the
ClO₂ production process as depicted in the flow charts and diagrams provided.

1. Initial Brine Solution and Weak Chlorate

• Brine Solution (NaCl 300 GPL): The process begins with the
preparation of a brine solution, which is fed into the reactor.
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 • Weak Chlorate: This stream is combined with the brine solution to
initiate the process.

2. Electrolysis

• Electrolyser: The brine solution is subjected to electrolysis, where it

splits into sodium chlorate (NaClO₃) and hydrogen gas (H₂).
• Degasifier: The generated H₂ gas is separated from the chlorate solution.

3. Hydrogen Scrubbing and Cooling

• H₂ Scrubber: The separated H₂ gas is scrubbed to remove impurities.

• H₂ Cooler and Demister: The scrubbed H₂ gas is cooled and any
remaining moisture is removed through demisting.

4. Chlorate Concentration

• Strong Chlorate (NaClO₃): The solution is concentrated to form a

strong chlorate solution (490 GPL NaClO₃).
• Strong Chlorate Cooler and Filter: The concentrated chlorate is cooled
and filtered to remove any solid impurities.
• Chlorate Chiller: Further chilling of the strong chlorate solution is done
to optimize its temperature for subsequent reactions.

5. HCl Synthesis

• H₂ to HCl Synthesis: The excess H₂ gas is directed to the HCl synthesis

unit.
• HCl Furnace and Absorber: Hydrogen reacts with chlorine to produce
HCl gas, which is then absorbed in water to form hydrochloric acid (32%
HCl).

6. ClO₂ Generation

• ClO₂ Generator: The strong chlorate reacts with the generated HCl in
the ClO₂ generator to produce chlorine dioxide gas.
• Dilution Air and Recycle Gas: The gas mixture is diluted and partially
recycled to maintain process efficiency.

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 • Weak Chlorate Evaporator: Any remaining weak chlorate solution is
evaporated to recover useful components.

7. ClO₂ Absorption

• ClO₂ Absorber: The ClO₂ gas is absorbed in chilled water (7°C) to form
a ClO₂ solution at the desired concentration.
• ClO₂ Storage and Pump Tank: The ClO₂ solution is stored and pumped
as needed for further use or dispatch.

8. Tail Gas and Waste Management

• Tail Gas Scrubber: Residual gases from the process are scrubbed to
remove harmful components before venting.
• Recycle Acid: Acidic waste streams are recycled back into the process to
minimize waste and improve efficiency.

Chemical Reactions Overview

Electrolysis of NaCl:

2NaCl+6H₂O+Electricity→2NaClO₃+6H₂

ClO₂ Generation:

2NaClO₃+4.8HCl→1.8ClO₂+2NaCl+2.4H₂O+1.5Cl₂

HCl Synthesis:

2.4H₂+2.4Cl₂→4.8HCl

The overall reaction simplifies to:

0.9Cl₂+3.6H₂O+Electricity→1.8ClO₂+3.6H₂

This integrated process ensures efficient production of ClO₂, with minimal

waste and optimized use of raw materials.

Producing ClO₂ on-site rather than purchasing it directly offers several

advantages, which can be crucial for industries like TNPL that require large
quantities of chlorine dioxide. This includes:-

1. Cost Efficiency
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Lower Costs: Producing ClO₂ on-site can be significantly cheaper than
purchasing it due to the high costs associated with transportation and handling
of this hazardous chemical.

Raw Material Savings: The process utilizes readily available and relatively
inexpensive raw materials like sodium chlorate (NaClO₃), sodium chloride
(NaCl), and hydrochloric acid (HCl).

2. Safety and Handling

Reduced Transportation Risks: Chlorine dioxide is a highly reactive and
unstable gas, making its transportation dangerous and expensive. Producing it
on-site eliminates the need for transporting large quantities, thereby reducing
associated risks.

Improved Safety: On-site production allows for the controlled generation of

ClO₂ in quantities that are immediately used, minimizing the storage of large
amounts of this reactive chemical.

3. Freshness and Quality

Higher Purity: On-site production ensures that the ClO₂ is fresh and of high
purity, which is critical for its effectiveness in applications such as bleaching in
the paper industry.

Consistent Supply: In-house production ensures a consistent and reliable

supply of ClO₂, avoiding potential supply chain disruptions that can occur when
relying on external suppliers.

4. Environmental Benefits
Reduced Emissions: On-site production can be optimized to minimize
emissions and waste, making it more environmentally friendly. Recycling waste
streams within the process can further enhance environmental performance.

Lower Carbon Footprint: By eliminating the need for transportation, the

carbon footprint associated with the production and supply of ClO₂ is
significantly reduced.

5. Operational Control
Flexibility: On-site production offers greater flexibility to adjust the production
rate according to the plant's immediate needs, ensuring optimal use of resources.
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Control over Process: Direct control over the production process allows for
continuous monitoring and improvement, leading to better efficiency and
reduced operational costs.

6. Economic Incentives
Capital Investment Payback: Although setting up an on-site production
facility requires capital investment, the savings from lower purchase costs,
transportation, and handling often result in a quick payback period.

Long-term Savings: Over time, the cumulative savings from producing ClO₂
on-site can be substantial, contributing to the overall profitability and
competitiveness of the company.

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33 | P a g e
34 | P a g e
 Paper Machine
The basic ingredients of paper include fibers from Bagasse,Hard Wood,Dip and
from Imported pulp in the ratio of 60% Bagasse Fibers,30% Hard Wood Fibers,
Imported pulp and De-inked Pulp jointly contribute 10% of the total pulp
supplied for the paper production.

In TNPL we have 3 storage tanks for Bagasse Pulp storage,2 tanks for HW pulp
storage,1 storage tank for De-inked pulp.According to the clients specification
and needs ,the pulp quantity of these available pulp are supplied to paper
machine after mixing them in a reactor,this step is called as Stock Preparation
and Blending. We also add Fillers and other chemical additives needed to
achieve the client specified properties of the paper.The general process in detail
is given below:-

Paper Manufacturing process in Paper Machine:-

1. Stock Preparation

◆ Refining: The pulps is mechanically treated to improve fiber bonding.

◆ Beating: Further mechanical treatment to enhance paper quality.

2. Blending

◆ Mixing: Different types of pulp are blended together to achieve the

desired paper characteristics.
◆ Additives: Chemicals (fillers, dyes, retention aids) are added to the pulp
to enhance specific properties of the paper.

3. Cleaning

◆ Centrifugal Cleaners: Remove heavy contaminants from the pulp

slurry.
◆ Pressure Screens: Further clean the pulp to remove finer contaminants.

4. Screening

Fine Screening: Additional screening to ensure only clean, uniform

fibers proceed to the paper machine.

5. Wire Section (Forming Section)

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 ◆ Headbox: Delivers a uniform slurry of pulp onto the moving wire or
fabric.
◆ Forming Fabric: The pulp slurry is spread and begins to form a
continuous sheet as water drains through the fabric.
◆ Drainage Elements: Various elements (foils, vacuum boxes) help
remove water from the slurry, consolidating the fibers into a wet sheet.

6. Press Section

◆ Press Rolls: The wet sheet is passed through a series of press rolls to
remove additional water.
◆ Felt: Absorbent fabrics (felts) assist in water removal and transport
the sheet through the press section.

7. Drying of Paper

◆ Dryer Section: The paper sheet is passed over a series of steam-

heated cylinders to evaporate remaining water.
◆ Air Dryers: Additional drying may be achieved using hot air dryers.

8. Surface Sizing

◆ Size Press: A coating of starch or other sizing agents is applied to the

surface of the paper to improve strength and printability.
◆ Drying Cylinders: The coated paper is dried again to remove
moisture from the sizing application.

9. Reeling and Winding

◆ Reel: The continuous paper sheet is wound onto a large reel at the end
of the paper machine.
◆ Winder: The large reels are then slit into smaller rolls (child reels) to
meet customer specifications.
10. Cutting of Child Reels
Sheeter: The child reels are cut into sheets if required, depending on
customer orders.
11. Packing
Packaging: The rolls or sheets are wrapped and packed to protect them
during transportation and storage.
12. Stacking
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Palletizing: The packed paper products are stacked onto pallets for efficient
handling and storage.

13. Dispatch

Loading: The finished products are loaded onto trucks or other

transportation modes for delivery to customers.

This comprehensive process ensures that TNPL produces high-quality paper

efficiently and meets customer requirements while maintaining environmental
and operational standards.

The Unit Operations and Unit Processes involve in the Paper Machine are:-

Unit Operations:

❖ Mechanical Treatment: Refining, beating.

❖ Separation: Cleaning, screening, dewatering in the wire and press
sections.
❖ Heat Transfer: Drying cylinders, air dryers.
❖ Coating: Surface sizing.
❖ Cutting: Slitting, sheeting.

Unit Processes:

❖ Chemical Additions: Blending, surface sizing.

❖ Physical Forming: Sheet formation in the wire section.
❖ Water Removal: Press section, drying section.
❖ Packaging: Packing, stacking, dispatch.

In TNPL currently three Paper Machines are in use namely PM1,PM2,PM3.The

major difference between these three are:

1) PM1 VS PM2:-

PM1 has Size Press, which allows the paper produced in PM1 to have both
internal addition of starch and external coating of starch, but PM2 does not have
Size press which makes the paper produced to be hard and less in brightness
compared to PM1 as only internally starch can be added that too at the Blending
Stage.

2) PM1 VS PM3:The PM3 is a newly established Paper machine in TNPL

which makes it technologically advanced ,so the production capacity being 600

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metric tons per day while in PM1 capacity of paper production is 300 metric
tons per day and high-quality end paper can be produced in PM3.

Feature PM1 PM2 PM3

Modern, high-speed paper

Type Traditional paper machine Traditional paper machine
machine

Capacity ~300 MTD ~400 MTD ~600 MTD

High-quality printing and

Newsprint, writing/printing Newsprint,
Products writing paper, copier paper,
paper writing/printing paper
coated paper

Higher proportion of
Raw Hardwood and softwood Hardwood and softwood
chemical pulp, high-quality
Materials pulp, recycled fiber pulp, recycled fiber
recycled fiber

Conventional technology, Conventional technology, Advanced technology,

Technology
basic automation basic automation sophisticated automation

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 Feature PM1 PM2 PM3

Premium printing and

Newspapers, textbooks,
Newspapers, textbooks, writing applications (e.g.,
notebooks, general-
End Uses notebooks, general-purpose copier paper, high-end
purpose writing and
writing and printing papers stationery, magazines,
printing papers
brochures)

PM3:-

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 R&D AND QUALITY CONTROL

The R&D department at TNPL is at the forefront of innovation in the pulp and
paper industry, dedicated to enhancing product quality and sustainability. By
meticulously analyzing various factors such as brightness, strength, and pulp
content, the team ensures that the paper produced meets the highest standards.
Their expertise extends to the evaluation of different wood species, with a
notable focus on eucalyptus trees and Casuarina Tree, which have been
identified as economically viable due to their high pulp content and ease of
growth. The department also engages in advanced horticultural practices,
selectively breeding trees and sugarcane varieties with enhanced fiber content to
support both environmental and economic goals. Through these comprehensive
research initiatives, TNPL's R&D department plays a crucial role in driving
sustainable advancements in the industry.

40 | P a g e
Analysis of Pulp Content in Various Woods
• Eucalyptus Trees: Identified as having sufficient pulp content and being
relatively easy to grow, making them economically viable.
• Horticulture and Selective Breeding: TNPL selectively breeds trees
with higher pulp content. These saplings are then sold to farmers,
promoting the growth of economically viable tree species.
• Regular Measurements: The R&D team regularly measures the pulp
content in various woods, evaluating their economic viability,
environmental impact, growth time, water requirements, and land
occupancy.

Studies on Sugarcane
• Research on Sugarcane Types: Studies have been conducted on various
types of sugarcane for their pulp content.
• Issue with Sugar Industry: Despite developing sugarcane varieties with
higher fiber content, the sugar industry does not favor these types as they
are the providers of bagasse.
• Horticulture of High Fiber Sugarcane: Researchers have developed
horticulture practices for sugarcane with increased fiber content, aiming
to improve the raw material for pulp production.

Brightness and Surface Sizing

• Brightness: This is a critical quality parameter in paper production,
indicating how much light is reflected from the paper surface.
o Before Surface Sizing: The initial brightness of the paper before
any treatment.
o After Surface Sizing with Starch: The brightness improves with
the addition of starch
o After addition of fillers: there semes to be an improvement
brightness around 10% compared to the one with the surface sized
starch.
• Relationship with Yellowness: Brightness is inversely proportional to
yellowness; as brightness increases, yellowness decreases.
• pulp sample form the pulping mill: where the bleahing agents are
added to remove the lignin after each press where they analyse the
41 | P a g e
 brightness content and measure the amount of chemicals required this is
done for both bagasse and hard wood

Role of Starch in Surface Sizing

• Cation-Anion Interaction: Starch, being a cation, binds effectively with
the anionic fibres in paper. This interaction enhances various properties
of the paper:
o Improved Binding: The cation-anion attraction holds the paper
fibres together more firmly, making the paper harder to tear.
o Increased Opacity: Starch helps in improving the opacity of the
paper.
o Reduced Water Absorption: It also reduces the paper's water
absorption capacity, adding to its strength and durability.
• Multipurpose Use: Given its multiple benefits, the amount of starch
added must be carefully regulated, a task managed by the R&D
department.

Filler Materials
• Primary Role: Filler materials are mainly used to improve the brightness
of the paper. Unlike starch, they do not contribute to other physical
properties. Ash(caco3) is a great example of filler due to its cheap
availability when added to paper it also increase the total volume of
output to increase bringing more profits.

Other Measured Properties

In addition to brightness, the following properties are also measured to ensure
the quality and performance of the paper:

• Bulk: The thickness of the paper relative to its weight.

• GSM (Grams per Square Meter): The weight of the paper, which is a critical factor in
determining its usage.
• Tensile Strength: The maximum stress the paper can withstand while being stretched.
• Tear Strength: The resistance of the paper to tearing.
• Bursting Strength: The pressure required to burst the paper.
• Pulp Freeness (CSF - Canadian Standard Freeness): Measures the rate at which water
drains from a pulp suspension, indicating the fibber’s refining degree and drainage properties.

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The ABB Quality Control System (QCS)
In the paper production process, maintaining high standards of quality is
paramount. The ABB Quality Control System (QCS) is a state-of-the-art
scanning machine installed before the reeling of paper. This advanced system
continuously monitors and measures the paper properties, ensuring they adhere
to the stringent quality standards and meet customer requirements. By providing
real-time data and feedback, the ABB QCS enables precise control over the
paper-making process, thereby enhancing the overall efficiency and quality of
the final product. Honeywell software is used to read the data from the ABB
machine.

Properties Measured by the ABB Quality Control

System (QCS)
• Basis Weight (GSM): Measures the weight of the paper per unit area to
ensure uniformity and adherence to specifications.
• Moisture Content: Monitors the moisture level in the paper, which is
crucial for maintaining the desired paper strength and printability. The
moisture content in the paper should be around 5-6%, if it was any lower
the paper would crumble
• Thickness/Bulk: Ensures consistent paper thickness, which affects the
paper's feel and handling characteristics.
• Brightness and Color: Measures the reflectivity and color of the paper
surface, ensuring visual quality and consistency.
43 | P a g e
 • Opacity: Assesses the paper's opacity, which is important for print
quality and readability.
• Ash Content: Determines the amount of filler material, which can affect
the paper's brightness and opacity.
• Calliper: Measures the thickness of the paper to ensure uniformity and
proper sheet formation.
• Tensile Strength: Assesses the paper's resistance to breaking under
tension, crucial for durability and performance.
• Formation: Evaluates the fibre distribution within the paper, affecting its
overall quality and printability.
• Smoothness: Measures the surface smoothness, impacting the paper's
printability and tactile properties.

By incorporating the ABB QCS into the paper production line, TNPL ensures
that each roll of paper meets the highest quality standards, aligning with both
industry benchmarks and specific customer demands.

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 CONCLUSION
During my internship at TNPL, I had the opportunity to gain valuable insights
and hands-on experience in the Kraft process of paper production. This
immersive experience provided me with a deep understanding of the intricate
processes involved and the importance of resource optimization and
environmental sensitivity.

Key Learnings and Experiences:

1. Pulp Production and Feed Requirements:
o I learned about the specific amount of feed required to produce
pulp, emphasizing the need for precise calculations to ensure
efficiency and quality.
2. Utilization of Bagasse and Wheat Straw:
o In Southern India, bagasse, a byproduct of the sugar industry, is
available in large quantities and is used extensively in paper
production.
o In contrast, wheat straw is preferred in Northern India.
o At TNPL, 60% of the paper is produced using bagasse pulp, which
is abundant locally. However, due to bagasse pulp's lower opacity,
tear resistance, and hardness, 30% hardwood pulp is added to
enhance these properties.
3. Selection of High Pulp Content Woods:
o The availability of high-pulp-content wood, such as eucalyptus and
Casuarina trees, is crucial for economic viability.
o It is important to source wood from nearby areas to reduce
transportation costs and environmental impact.
4. Recycling of Chemicals, Water, Energy, and Used Paper:
o I learned about the recycling processes at TNPL, such as the use of
lime in converting green liquor to white liquor, which produces
limestone and lime mud.
o We are also using 5% of De Inked Pulp which helps in recycling of
used paper and helps promote sustainability.
o Limestone is sent to the kiln, while lime is reused in the production
of white liquor, and lime mud is sent to cement plants, creating a
no-waste loop.
5. In-house Energy Production:
o TNPL's innovative approach to energy production includes using
methane gas from bagasse as a source of energy, significantly
reducing costs.

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 This in-house energy production not only lowers operational costs
o
but also reduces dependence on external energy sources,
contributing to overall sustainability.
6. Role of WETLAP in Pulp Storage:
o WETLAP is used to keep pulp in stock, providing a crucial buffer
when the pulp mill is out of commission.
o It involves pressing and dewatering the pulp to create dense, wet
sheets that can be easily stored and preserved for around 2 months.
o These wet sheets can be reintroduced into the production process
when needed or sold as a profit-generating product to other paper
manufacturers.
7. Importance of sprinklers is bagasse yard:
o Bagasse can easily catch fire and sand/dust could easily fly so it is
an issue which can be solved by spraying water. And the yard size
is 900m which is must be sprinkled and the water collected is sent
to waste water treatment plant

Overall, my internship at TNPL was an enriching experience that deepened my

understanding of the paper production process and highlighted the importance
of sustainability and resource efficiency in industrial operations.

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