Detailed Project Report on Paper Plant (Writing and Printing Paper)

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)