Industrial Visit Report

Hindustan Newsprints LTD

[HNL]

Presented by,

George Jose

M8B,8214

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Contents• Origin of HNL• Products • Purchase at Gate• Wood used• Technology Highlights• Plant and Machinery• Process• Making of Paper• Pollution Control• Achievements• Conclusion

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Origin of HNL• This Project was

conceived, as early as, in 1968

• Feasibility Report was prepared

• GoI took the decision in May, 1970 to approve this Project in principle

• In 1983, Kerala Newsprint Project commenced commercial operations

• The Indian government directed HPC to promote and incorporate as a government company.

• Under the Companies Act, 1956, took over and operate the said Newsprint Mill and to acquire all the properties and assets as well as all the debts and liabilities belonging to the Newsprint Mill.

• HPC promoted and incorporated Hindustan Newsprint Limited (HNL) as its fully owned Subsidiary

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Products & Product History

• Newsprint is used in the printing of newspapers, flyers, and other printed material intended for mass distribution.

• Diversity in range – Initially, the company produced 52 GSM (Grams per Square Meter)

newsprint.– Later commenced production of 48.8 GSM newsprint & 45 GSM newsprint.– Colour Standard / Pink, Brightness 55 - 58 %, ISO Size of reel 34 cm to 163 cm

• At the time of commissioning in 1982, newsprint had 48-50 % ISO brightness. – Later, it adopted a superior and eco-friendly technology in bleaching using

Hydrogen Peroxide (H202). – Enhanced the brightness to 53-55% ISO.– further advanced the brightness levels and is at present producing newsprint

with 55 - 58 % ISO.

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Purchase at Gate• The Purchase at Gate scheme was

launched by HNL as a complementary, programmed to Farm Forestry scheme. As per this scheme, pulp wood materials are purchased directly from farmers at a remunerative price at the company gate doing away with middlemen.

• Highlights of the HNL Purchase at Gate Scheme:• Launched in the year 1998. • Direct purchase of raw materials from farmers. • Farmers can bring in pulp wood directly to HNL gate and collect the

price immediately. • No middlemen involved – farmers get fair price for their produce. • Swings in the market do not affect the farmers as the demand from

the company is consistent. • A total of 4.27 lakh tonnes of material collected so far

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Wood used ….

• Pulpwood like Eucalyptus, Acacia, Mangium etc have found an alternative market as they are being purchased by plywood Industries paying a very high price, this made to use Tissue Culture bamboo

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Technology Highlights• Continuous up-gradation and improvisation in

technology for cost minimization and quality improvements.

• First Newsprint Manufacturer in India to integrate process automation covering all the plants.

• E-practices in all functional areas viz. purchase, distribution, finance, stores, HR, process and maintenance.

• Online Digital quality control system. • Incremental, significant technological

improvements in all critical areas.

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• Use of Hydrogen Peroxide for bleaching.• Installed and later upgraded the computer based Quality

Control System for Paper machine. • FBC conversion of Boilers. • Introduction of Distribution Control System for all mill

process operations. • Lime sludge re-burning plant for recovery of chemicals. • Energy efficient Falling Film Evaporator and Finisher in

Recovery plant. • Installed Fibre Optic LAN for mill-wide Computer

networking. • Implemented Enterprise Resource Planning (ERP)

software.

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Plant and MachineryPlant & Machinery Name of Manufacturer Year of

InstallationPaper Machine Voith, Germany 1982

Raffinator (CMP) Sunds Defibrator, Sweden 1982

Quality Control System in Paper Machine Measurex, USA 1991

Chemical Additive Plant Celleir, France 1982

Andritz Filter Press (ETP) Andritz, Austria 1993

Roll wrapping Machine Klienewefers, Germany 1982

Core making Machine Guschy Tannesmann 1982

Machine winder Jagenberg, Germany 1982 Turbo Generator BHEL, Hyderabad 1982 Power Boiler ABB 1982 Recovery Boiler BHEL, Trichy 1998 Evaporator - I L&T, Mumbai 1982 Evaporator - II Alfalaval, Pune 1994 De-Inking Plant Voith, Germany 2002

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Major Process Control SystemsDCS for Utility Plant Yokogawa Blue Star,

Bangalore 1995

DCS for Pulp Mills & Paper Machine

Yokogawa Blue Star, Bangalore 2002

Quality control System for Paper Machine

Honeywell Measurex, USA 2002

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Production Capacity

• HNL is one of the well performing PSUs in the State which is continuously registering profits since 1990.

Financial Year 2008-2009Production 10,8005 MT Sales 87,476 MTSales Turnover Rs 297.67 Cr Profit Before Tax Rs 21 Cr Profit After Current Tax Rs 12.64 Cr

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Process• Three grades of pulp:- Chemi Mechanical pulp,

Chemical pulp and De-inked pulp are blended to manufacture newsprint.

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Chemi Mechanical Pulp (CMP)• CMP plant (Sunds Defibrator, Sweden) • Uses hard wood(Eucalyptus , Acacia) chips to produce pulp.• Chips are washed, pre-steamed and impregnated with caustic

soda. • Impregnated chips is mechanically pulped using three

Raffinators.• Raffinators are driven by synchronous motors of 6.5 MW (BHEL

make).• Spent chemicals are removed after primary refining using Twin

roll press.• Pulp after second stage refining is washed and bleached by

Hydrogen Peroxide.• Bleached pulp after refining is sent to High Density storage

tower for onward use in paper machine.

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Chemical Pulping (CP)• Capacity of CP plant is 100 MT/day.• Reed/ Bamboo chips are pulped using

conventional KRAFT.(Sodium Peroxide+ Sodium Sulphide)

• After counter current washing, pulp is bleached using chlorine followed by Hydrogen Peroxide stage.

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De-Inking Plant (DIP)

• Uses Old Newspaper and Old Magazine Paper.• Waste paper is weighed and pulped in Batch Pulper

and stored in Dump Tower.• Pulp is cleaned off the contaminants using HD

cleaner.• A seven cell floatation process removes the ink

from pulp.

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• Pulp is then bleached using Sodium Hydro-Sulphite and stored in High Density storage tower.

• A Reject handling system separates the rejects for disposal at about 50% dryness.

• The sludge handling system thickens the ink sludge to 40% dryness for use in our FBC Boilers.

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Making of Paper• The CMP, CP and DIP are mixed in a

definite ratio and chemical additives are added.

• The paper machine approach flow system consists of four-stage centri-cleaner, primary fan pump and a variable speed secondary fan pump and pressure screens.

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• The paper machine is the modern high speed machine from VOITH, Germany.

• With the desired velocity, the diluted pulp flows from a high turbulance W-type head box into Duoformer twin-wire forming section.

• The paper web is formed in Duoformer and it is pressed to remove water with swimming rolls.

• The paper from the press section passes on to a dryer section, with 36 dryers and one sweat dryer, having thermo-compressor steam and condensate system.

• The dried paper surface is smoothened through a four roll stack.

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• The machine is designed for 750 meters per minute (mpm) speed with a deckle (width) of 6.85 meters to produce 44 to 54 GSM newsprint.

• The machine has a sectional D.C. drive with thyristor control.

• The finishing line has a VOITH winder, Jagenberg Salvage winder and Klienewefers roll wrapping machine. Paper core is made here in a spiral core making machine with purchased kraft paper and grey board.

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The Utilities• The steam requirement is met by 3 boilers with

fluidised bed burning.• There is a chemical recovery boiler of BHEL make.• There are two turbo generators with capacity of 15

MW and 7 MW.• Only 35% of total power requirement is met

through State Electricity Board. • The mill has an effective water and air supply

system for plant use and controls.

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Pollution Control• Unfailing attention on control measures and constant

monitoring on the results • Air pollution - Fully functional electrostatic precipitators

for all the boilers and lime kiln. • Water pollution - Fully equipped effluent treatment

plant. Quality of effluent discharge meets with all the norms specified statutory regulations / guidelines.

• Land pollution - Construction of a secured land fill facility for hazardous waste disposal.

• Integrated process automation covering all the plants-First Newsprint Industry in India to implement the same.

• E-practices in all functional areas viz. purchase, distribution, finance,stores,HR,process and maintenance

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Effluent Treatment• In keeping with National priorities and increasing

social obligations, HNL is ISO 14001 certified and has adopted environmental and pollution control measures.

• The colour and other pollutants are removed and water free from pollutants is discharged into the river.

• Air pollution is also controlled by effective Electro Static Precipitators.

Major consumers … MALAYALA MANORAMA MATHRUBHOOMI DESHABHIMANI INDIAN EXPRESS SANMARG ANANDA BAZAAR PATRIKA EENADU VARTHA DECCAN CHRONICLE DECCAN HERALD LOKPRAKASHAN DINAMALAR SANDESH RASHTRA DEEPIKA CHANDRIKA ANDHRA JYOTHI

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Achievements Kerala state energy conservation award 2013 National Energy Conservation Awards-2005 Awarded with “Two Leaves” rating in Pulp & Paper category in the

Green Rating exercise conducted jointly by Union Ministry of Environment & Forests (MoEF) and Center for Science & Environment (CSE) in the years 1999 and 2004.

HNL has bagged the Kerala State Pollution Control awards in 1997-98, 1999-2000 and 2002 for the best pollution control measures and processes adopted in the mill.

A survey of the Indian Pulp and Paper Industry, the first-ever "Green Rating" exercise in the country by the Centre for Science and Environment (CSE) and supported by the Union Ministry of Environment and Forest and the United Nations Development Program (UNDP) has rated HNL among the first five environment friendly paper mills.

CONCLUSIONHNL is the only mill in the country, which, in addition to

meeting all parameters for effluent treatment, de-colourizers the effluent before discharge

HNL is also the first to substitute 90% of chlorine in bleaching with environment friendly

Recycling , have helped to preserves forest materials from about 10,000 Ha. of land.

Implementation of farm forestry with the active participation of Voluntary / Non Governmental Organizations ((NGOs)

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Thank You