Z.H.

Sikder University of Science and Technology

Kartikpur, Shariatpur, Bangladesh

Project Title: The Manufacture process of

Paper from pulp.

Submitted By-
1. Debashis Kumar Bhaumik (170309002)
2. Mubashir Billah khan (170309013)
3. Md. Sohel Mia (170309018)
4. Md. Hafizur Rahman
Btch: 17th
Department of Chemical Engineering

Submitted To

Supervisor Co-supervisor

Ayesha Tazrin Dr. Hossain Mohammad Zakir

Lecturer Asst. Professor
Department of Chemical Engineering
Department of Chemical Engineering

Department of Chemical Engineering,

Z.H. Sikder University of Science & Technology
Shariatpur, Bangladesh
 Certification: This is to certify that, the Project titled “The Manufacture process of
Paper from pulp. It was carried out by Md. Sohel Mia and submitted to the Department of
Chemical Engineering, Z.H. Sikder University of Science & Technology as a partial fulfilment of the
requirement for the award of Bachelor of Science Degree in Chemical Engineering.

Supervisor:
Dr. Hossain Mohammad Zakir
Lecturer ……………………………….
Department of Chemical Engineering, ZHSUST (Signature & Date)

Ayesha Tazrin
Lecturer …………………………
Department of Chemical Engineering, ZHSUST (Signature & Date)

Declaration

I do hereby declare that the work presented in the Project report has been carried out by me under the
supervision of Dr. Hossain Mohammad Zakir (Lecturer) and the co-supervision of
Ayesha Tazrin(Lecturer), Department of Chemical Engineering, Z.H. Sikder University of Science and
Technology. The information are accurate and relevant data are authentic. The project has been
prepared and presented here collected from the practical field work, many books and with the help of
website. Neither the report nor any part of it has been submitted for any degree/diploma or any other
academic award anywhere before.

Sincerely Yours,
[Link] Mia
Batch: 17th
ID: 170309018 ………………………….
Department of Chemical Engineering, ZHSUST (Signature & Date)
 Acknowledgement

At the beginning, I remember almighty Allah, the beneficent and the merciful, for giving me the
opportunity and strength to carry out and complete the project work properly. Throughout this work, I
have been helped and guided by many people in many different ways.

First, I would like to express my best regards, profound gratitude, indebtedness and deep appreciation
to my honorable and beloved supervisor Dr. Hossain Mohammad Zakir (Asst Professor) and
C0-supervisior Ayesha Tazrin(Lecturer), Department of Chemical Engineering),
Z. H. Sikder University of Science & Technology, not only for their direct assistance but also stimulating
suggestions and excellent support that made this dissertation possible.

Specially thanks to my honorable guardian Engr. A.B.M Easin sir ( Advisor- Production &
Technical affairs, Paper sector- Bashundhara Group) for providing me scientific, practical and
inspiring guidance, enthusiastic encouragement, valuable suggestion.

I convey heartiest thanks to our respectfull teacher Md. Rahim Uddin, Co-Coordinator, Department
of Chemical Engineering, University of Z. H. Sikder University of Science & Technology, for his kind
co-operation and valuable help during my Project work. I also express my gratitude to all of my
respectful teachers of the Department of Chemical Engineering,
Z. H. Sikder University of Science & Technology.

Finally, I express appreciation to my beloved parents and other family members who sacrificed a lot
for carrying out this study.

Md. Sohel Mia

Contents: 1
Abstract………………………………………………………………2
List of abbreviation………………………………………………… 3

Chapter-1: Introduction……............................................................. (4-9)

1.1 The History of Paper………………………………………………
1.2 Grades of Paper………………………………………………………………...
1.3 Background of the Company …………………….…………………….
1.4. Factory Location ………………………………………………………….
1.5 Plant Layout……………………………………………………….
1.6 Feasibility survey…………………………………………………………………

Chapter-2: Process Description of Paper……………………………… (10-23)

2.1.1 Process in General …………………………………………………………...…
2.1.2..Process Unit ……………………….. ……...…………………………………..
2.1.3 Process Equipment’s……………………………………………………………
2.1.4 Chemical Additives………………………………………….......................
2.1.5. SOP of Chemicals ………………………………………………………
2.1.6 Raw Materials and Filler …………………………………………………………
2.2.1 Paper Machine 01………………………… ………………………………….
[Link] Machine 02 ……………………………………………………………,,.
2.3 Block Diagram ………………………………………………………………………
2.5. P & I diagram of Paper Machine……………………………………...

Chapter-3: Material and energy balance…………………………......….... (24-27)

Chapter-4: Cost estimation………….………………………………............... (28-32)

Chapter-5: Safety & HAZOP………………………………………............... (29-36)

5.1 Industrial safety…………………………………………………………………...
5.1.1 Important of Safety……………………………………………………...............
5.1.2 Response of safety……………………………………………............................
5.2 Safety rules………………………………………...................................................
5.3 Safety Sign………………………………................................................................
5.4 HAZOP analysis……………………………………………...................................

Conclusion………………………………………………………………........ ( 38-40)
References………………………………………………………………………….......
 02

Abstract
In accordance with requirements to be fulfilled under module ChE-425*- Project,
I am assigned to Bashundhara Multi Paper Industrise Limited for the purpose of
project work on ‘The Manufacture process of Paper from pulp.
. The report that follows contain a detailed methodology of the approach adopted in this
regard- which includes a comprehensive survey of available literature and an overall
selection of a manufacturing process; the feasibility of the design in terms of safety,
environmental and economic aspects, a detailed balance of mass and energy of process
and utility flows required, and a set of diagrams depicting the process flow and flow
sheets of mass and energy.
Bashundhara Multi Paper Industrise Limited is the biggest paper mill in Bangladesh.
The plant Bashundhara Multi Paper Industrise Limited was carried out to produce
different type of paper 100000 MT every year, it was revealed and concluded by us that
the products are produced by the Programmable Logic Controller (PLC) with the QCS
system in which terms of its economic feasibility, product quality and
environmental impact.
 03

List of Abbreviations
BMPIL Bashundhara Multi Paper Industrise Limited
SP Stock Preparation
PM Paper Machine
EIA Environmental Impact Assessment
FTI Flow Transmitter Indicator
LTI Level Transmitter Indicator
MSDS Material Safety Data Sheet
MTPD Metric Tons per Day
BSI The British Standard Institution
ISO International Standard Organization
SV Set Values
PV Process Value
OSHA Occupational Safety and Health Administration
PFD Process Flow Diagram
PPE Personal Protective Equipment
SOP Standard Operational Proce
 Chapter-1 04

Introduction

1.1. The history of paper: The history of paper is also the history of human culture and
civilization. The Egyptians, Greeks and Romans wrote on “papyrus”, a paper-like material.
Today’s kind of paper was first developed and used in China. Paper was the most important carrier
of information in the past. It was only with increasing paper production that the transfer of
knowledge, education and information to a larger portion of society became possible. With paper
emperors were able to administrate large empires more easily. In former times paper was a valuable
product, and paper making an art – an art that was often kept secret because of the outstanding
advantages of the product. Today paper has changed from a rare artisan material to a commodity
product, with a high practical value in communication, in educational, artistic, hygienic, sanitary,
and technical applications. Nobody can imagine a world without paper. A large variety of paper
grades are produced to suit the special requirements of each application: Graphic paper grades,
packaging papers and board, hygienic papers, and specialty paper grades. Paper can be
impregnated, coated, laminated, creped, molded etc. Paper products embellish our homes, and
sanitary products made of paper easy our daily life. An easier life is also more likely with a
sufficient number of banknotes in the briefcase. Packaging papers and board grades support
supermarket logistics and product presentations. Computer print-outs and other graphic papers
such as newspapers, magazines and books accompany us through our life. Even today in our digital
world paper is a reliable means of long-time documentation and data preservation. The worldwide
consumption of paper is increasing steadily over the years. The paper consumption in individual
countries is related to their gross national product and hence the further increase in paper and board
consumption will be different in different countries depending on whether economic saturation, as
e.g. in the United States and Central Europe, or fast increasing demand, as in China, is prevailing.
The ratio of the worldwide consumption of the different paper and board grades has changed in the
past and will change in the future according to technical and social evolution and developments in
the individual countries and in the world as whole. Today recovered paper has become the main
resource for paper and board production, followed by chemical pulp, mechanical pulp, pigments
and fillers, and chemical additives. Paper is mainly based on fibers from cultured woods, and is a
renewable and recyclable raw material. The special characteristic of this fiber material is that the
paper strength results from the hydrogen bonding between the individual fibers. In certain cases it
is enhanced by the addition of starch or wet strength additives. The hydrogen bonds are loosened
by rewetting the paper which allows easy recycling. Increased paper recycling and sustained
foresting help to preserve the wood resources of the earth. The paper industry has steadily improved
its standards in complying with environmental demands as related to water consumption and water
effluents, energy consumption, primary (and secondary) fiber consumption. These standards have
to be maintained and even improved in the future because of further increasing paper and board
consumption and limited resources. The paper and board market is global, and so is the paper
industry where an evident consolidation has occurred over the last decades: In 1980 the 150 biggest
companies contributed about 45% to the overall production, in 2000 this figure was about 70% in
a market which had nearly doubled from about 170 million tons/year to about 320 million
tons/year.
 05
1.2 Grades of paper There are seven basic grade (types) of printing papers.
Bond or writing : usually use for letterheads, Business forms & copier.

Book : The most commonly used coated & un-coated papers for printing. Book papers are used for
trade & textbook as well as general printing.

Text : High quality sheet in a variety of surface & colors.

Cover: Used when greater bulk is required such as book covered, postcard, businesscard.

Tag: Tag stock has good banding or folding qualities, suitable bursting & tensile strength.

Bristol: is one of the board grades. It is economical substitute for cotton fiber stock.

Index Papers : have two outstanding characteristics stiffness & receptivity to printing ink.

1.2.1 Grade categories on Basis weight based:

. Tissue: Low weight, Bellow 40 g/m2

. Paper: Medium weight 40-120g/m2

. Paper board : Medium High weight 120-200 g/m2

. Board: High weight above 200 g/m2

1.2.2 Grade categories on Color based:

. Brown: Unbleached
. White: Bleached
. Colors: Bleached & Die or pigmented

1.2.3 Grade categories on Usage based

. Industrial: Packaging, wrapping, Filtering, Electrical etc.
. Cultural: writing, printing, newspaper, currency etc.
. Food: Food wrapping, candy wrapping, coffee filter, tea bag etc.

1.2.4 Grade categories on Raw material based

. Wood: Contain fibers from wood
. Agricultural residue: Fibers from straw, grass, bamboo, or other annual plants.
. Re-cycled: Recovered or secondary Fiber .
 06
1.2.5 Grade categories on Surface treatment based
. Coated: Coated with clay or other mineral
. Un-coated: No coated
Laminated: aluminum, poly etc.

1.2.6 Grade categories on Finish based

. Fine/Cours
. Calendar/super calendar
. Machine Finished (MF) or Machine Glazed (MG)
. Glaze/Glozed

1.2.7 Wide variety properties of writing printing paper (WPP):

. Mechanical Pulp: Newsprint, SC Paper ( Super calendar), Coated mechanical papers
Chemical Pulp: Un-coated fine papers , Coated fine papers, Special fine papers

1.2.8 Wide variety properties of Copy and Imaging Papers:

. Photographic paper
. Blue print Diazo paper
. Carbon less paper
. Thermal printing paper

1.2.9 Wide variety properties of Special fine Papers:

. Security Paper
. Artistic Paper
. Tracing paper
. Plotting Paper
. Luxury Stationary Paper

1.2.10 Wide variety properties of Paper board grade:

. Carton board: Folding boxboard (FBB), Solid bleached board, Liquid packaging board
. Container board: Linier board, Corrugating Medium
. Special board: Wallpaper base, Core board, Plaster board

1.2.11 Wide variety properties of Special strong paper:

. Abrasive paper
. Spinning Kraft
. Hunting Cartridge Paper

1.2.12 Wide variety properties of Electrical paper:

. Cable paper
. Capacitor tissue
. Transformer board
. Conductive board
. Creped paper
 07

1.3 Background of the Company

Bashundhara Multi Paper Industrise Limited is a leading edge Paper manufacturing company,
based in Narayongong, Bangladesh with a set up to manufacture and market world class paper with
outstanding product quality, product development capabilities and outstanding services. In this modern
age of competition, BMPIL have produce different grade of paper ( white writing printing, offset, off-
white, Brown- Liner, medium, packing paper & etc.
Bashundhara Multi Paper Industries Limited (BMPIL) is a sister concern of Bashundhara group. Beginning of
the 21th Century BMPIL starts its journey as the update biggest paper Industry in Bangladesh. Significantly
related to all the hopes and expectations of the new century, It has incorporated most advanced state of the art
technologies, machineries and equipment’s.

1.4 Factory Location

Bashundhara Multi Paper Industrise Limited (BMPIL). is located on

Newown , Sonargaon, Narayanganj. Bangladesh.
It is also located beside the river of meghna. s
1.5 Plant Section
The laying out of a plant is still an art rather than a science. Plant Layout is the physical arrangement
of equipment and facilities within a Plant.

A list of items that should be placed downwind of the processing facilities is given below

Admin Building

Stock Preparation Area

Paper Machine-01

Paper Machine-02

Main Lab

Mechanical and other shops

Finishing

Where House & Delivery point

Cafeteria

Store

Medical Center
 08

Fire station

Boiler house

Power Plant

Electrical Substation

WTP plant

ETP Plant

PCC Plant

WGCC Plant

Air compressors

Parking lot

1.6 Feasibility Survey

Feasibility survey is the pre-pivotal task to establish a plant profitably. Some key factors are necessary
to analyze for the feasibility survey of a plant. For Bashundhara Multi Paper Industrise Limited (BMPIL),
the important key factors are listed bellow

❖ BMPIL are used different type of raw materials for produced different type of paper at same Machine
❖ Availability of labour: Expert labours are available & there accomodation is also feasible by easy
transportation cost as BMPIL situated at Dhaka area.
❖ Power: As our government can not provide electricity at low cost, So BMPIL produce their
electricity as they need. They 25.5 MW power generation capacity to fulfil their need. They use
natural gas to produce electricity .
❖ BMPIL uses surface water for their utility. Water is collected from meghna river. So they can
manage their necessary amount of water easily.
❖ Process water & drainage water properly re-use in process.
❖ There are use profitable filler from own PCC & WGCC Plant.

09
❖ Raw material (Fiber) recovery system is very good & it properly re-use in process.
❖ Transportation cost: Their transportation cost lower enough on the roads because of their industry
situated at Narayanganj Near city of Dhaka. For export loading easily use of shipping at plant site.
❖ Buyer can easily collect product produced by BMPIL.
❖ Another important thing is that disposal treatment. After treatment they can easily through it to the
river. They have good treatment system for their both effluent and disposal.
BMPIL is the biggest Paper Industry in Bangladesh.

❖ So above discussion proved that BMPIL is quiet feasible both economically & environmentally
 10

Chapter 2
Process Description of Paper
2.1.1 Process in general

BMPIL Paper Machine-01 is Four diner Hi-Speed Paper Machine PM-01 use Quality Control System (QCS)
Automation system and
Paper Machine-02 is Module Jet Hi Speed Paper Machine. PM-02 use Quality Control System (QCS)
Automation system, PM-02 Basis weight & profile control by dilution water.

2.1.2 Process unit: The main process units of BMPIL are listed below:

I. 25.5 MW power plant including diesel generator.

II. 1000 MT water capacity WTP Plant,

III. Stock Preparation Unit

IV. Paper Machine-01

V. Paper Machine-02

VI. 250 MT water Capacity ETP Plant for process water treatment & water re-use.

VII. DM plant for water safely use for boiler.

VIII. Air Compressors for supply of Air.

IX. PCC & WGCC Plant for using of Filler in paper process.

11
2.1.3 Process Equipment’s

• Belt Conveyor
• Chain Conveyor
• Hydro Pulper
• Clarifier
• Krofta
• TDR (Triple Disk Refiner)
• HDC (High density Cleaner)
• LDC (High density Cleaner)
• Magnetic Separator
• Deflaker
• Decollator
• Pressure Screen
• Vibrating Screen
• Dryer
• Condenser

• Heat Exchanger
• Blower
• Compressor

Hydro Pulper. Hydro pulper is a giant paper industry blender. It is used to process fibrous materials (such
as recycled paper) into a usable slurry for manufacturing processes. They are used primarily in the pulp and
paper manufacturing industry.

Triple Disk Refiner (TDR): Refining is seen as the “backbone” unit process during paper-making.
The unit equipment is a hydraulic machine; with complex flow conditions and a heat transfer
process. The repeated cyclic crushing or beating of pulp fibres in a refiner is enabled by the use of
rotor and stator, and these are fitted with bars and [Link] refining process consumes huge
amount of energy and the principal forces involved during pulp refining include; normal force
compressing or crushing the fibre mat, corner forces at the edges of the refiner bars and the shears
forces generated by bar surfaces. It is worth noting that paper-strength improvement in relation to
refining or fibre beating improve fibrillation, fibre flexibility as a result of improve hydration (water-
uptake) of fibres, and as well enhance fibre swelling resulting to improve fibre bonding properties
during paper formation.

12
2.1.4: Chemical Additives:

Given below the chemicals additives of use & their measures quality specification for writing
printing paper :

Important specification that

SL. Category
Chemicals Name Purpose of use measures quality of the
No. Name chemicals

Coloring
1 Cartasol brilliant violet Shade maching
Agent
AKD(Alkaline ketone
2 Sizing Agent Internal sizing pH & Solid content
diamer)
To enhance paper wet
strength retention, improve
paper quality, reduce dusting Brightness,Moisture ,pH,
Modified cationic Quality
3 ,Linting & size addition & also DS & Nitrogen content ,
starch control
allowed using more filler & Viscosity
also reduce the tendency of
deposition

Retention For reteining the fiber & filler

4 Celfloc 640 Solubility , Density
aid & chemical
Prevent to produce bacteria
5 Nipacide CI- 15 Biocide Physical form,pH
in fiber
PAC(Poly Aluminium Appearance, pH, % Al2O3,
6 Coagulant For Controlling pH
Chloride) Solubility
OBA(Optical Brightening To Enhance the whitening
7 pH, Density & Brightness
Brightening Agent) Agent appearance of paper
Surface For increasing strenght & pH,Moisture,Ash,Brightness
8 Tapioca starch- F
sizing smoothness & viscosity
pH & Solid content &
9 Cartacol - SA liquid Sizing Agent Surface sizing
viscosity
10 Cartabond - EPI liquid Cross-linker Use as binder & surface sizing pH , solid content
For Controlling viscosity of
11 Enzyme Optimize Catalyst
Tapioca Starch
Anti foaming
12 Defoamer For removing the foam
agent
Use for retening fiber , filler &
13 Ivax poly Tc Fixing Agent Solid Content
chemical
14 Rill 100 Flocculant For settling the fiber & filler Settling properties
Cleaning For wire cleaning & use for
15 Caustic pH , % of NaOH
agent boiled out the system
Cleaning
16 Sulfomic Acid For cleaning wire pH
agent
Cleaning
17 Detergent For cleaning press felt Hydrophobic properties
agent
 13

2.1.5 SOP of Chemicals:

SOP for Sizing Chemicals:

1. Add 120 kg Cartacol- SA & 240 Kg Cartabond- EPI in IBC tank

2. Transfer the mixture to sizing agent IBC service tank by gravity force.
3. Transfer the mixture from IBC service tank to two Nos. supply tank(Top & Bottom) as per need.

SOP for OBA :

4. Add 500 litre water at OBA IBC tank & then add 250 L OBA.(1 OBA : 2 H2O)
5. Transfer the solution to OBA IBC service tank by gravity force.
6. Transfer the solution from OBA IBC service tank to two Nos. supply tank(Top & Bottom) as
per need.
SOP for Starch Preparation:
7. Add starch(Dry) into silo
8. Then tranfer dissolving tank by screw conveyor.
9. Add water(by automation system) into dissolving tank(Concentration 16-18 %)
10. Add enzyme by automation system(1.8 kg/MT of starch)
11. Transfer the solution to the cooker-1 through basket filter, temperature 80oC.
12. Transfer the solution from Cooker-1 to converter tank & then transfer the solution to
cooker-2 ,temperature 1200C.
13. Transfer the solution to steam separator tank & then to storage tank.
14. Transfer the cooked starch to supply system(two supply tank) by screw pump &
pressure screen.
2.1.6 Raw materials & Filler

There are main raw material of Chemical pulp,

Wastage pulp, broke, occ & NDLKC
Precipitate Calcium Carbonate (PCC) & Wet Graound Calcium Carbonate (WGCC)
filler widely used in paper process.

Raw materials consumption Furnish WPP(White Writing Printing) Paper

Furnish Percentage
LBKP 65 %
NBKP 5%
Broke 10%
Ash (Filler) 10 %
Moisture 5%
Others Chemicals 5%
 14
2.2.1 Paper Machine 01
Paper Machine 01 is a rebuilt fourdrinier high speed writing and printing paper machine.
Basis Weight range: 45-175 gm/ m2
Paper machine consists of Process approach flow system, Head box, Wire part with twin wire, suction
couch, suction pick up, Twin var press, Third press ,Smoothing press, pre Dryer, inclined pond type
size press, Hard nip calendar, reel section and rewinder.

APPROCH FLOW SYSTEM:

Approach system consists of full 4- stage cascade system low density cleaner (LDC) which helps to
remove dirt, Decollator system can carry out the complete deareation by removing of entrained air and
dissolved gases, Head box screen separates the larger and heavy particles from the stock . Pulse
attenuator is fitted in between the head box screen and head box. One air shower is installed at upper
side of the attenuator. The pressurized air is supplied at the upper side of attenuator. Pulsations may
be a case of basis weight variation. Low pulsation is dampened by this cushion effect.

CONVER FLOW SHEET HEAD BOX:

The stock reaches the head box on the front side of the machine through the rectangular header. On
end of header is fitted with an adjustable outlet for recirculation max.10% of inlet flow. A sight glass
is fitted on the back side of header to balance the pressure. Both side differential pressure transmitters
are fitted to automatically control he recirculation ratio. Converflow sheet, Basis weight valve, Wire
and Fan pump interlocking system, Total operating head, Slice section almost same.
head box consistency 0.9%- 1.0%. For better formation and strength properties consistency should be
reduce according to GSM.

FOURDRINIER SECTION:
Wire part is consists of top and bottom wire. Bottom wire carries 60-70% moisture and Top wire 30-
40%. Top wire drainage ratio 25-35%.Top wire having 3 Duo-D box chambers with sheet transfer box
and top wire cleaning box.
Duo-D box main work to increase the drainage, Cleaning box is used to clean the top wire and sheet
transfer box transfer the paper web from top wire to bottom wire. In bottom wire having 5 suction flat
box. Bottom wire use different angle blade.

PRESS PART:
Press part comprises pick up roll, 1st press, 2nd press, 3rd press and smoothing press. Pick up, 1st
press and 2nd press (Twine var press).

DRYER SECTION:
Dryer section consists of pre dryer and post dryer. Out of 46 cylinder pre dryer contain 32 cylinder and
post dryer 14. Multi cylinder with closed geared. 33 and 34 no. of dryer covered with Teflon coating.
35 and 36 are covered with chrome plated and Last cylinder having cooling water system. For all
dryer cylinders’ steam supply and condensate discharge are executed on the drive side. Rotary siphon
is fixed inside of the dryer cylinder.
Total dryer section having hood exhaust fan, heat exchange, hot air blower and pocket ventilation
system and differential pressure etc. There are 31 controllers in panel board to monitor the main steam
pressure, group wise steam and differential pressure etc.

Size Press Section:

Size press top roll is stationary micro rock and bottom roll is rubber covered moving [Link]
press installed one spreader roll which is Teflon covered.
Type : Inclined 2 roll size press pound type.
 15
Nipload : 45 kg/cm (Max)
Operating 25kg/cm
Niploading: Air bellows type.

Calendar SECTION:
We know the purpose of calendaring to modify the surface characteristics of the paper. These are
mainly:
1)Gloss 2) Smoothness 3) Density 4) Brightness 6) Opacity
Type : Open frame, 3 stages, 2 Nips
Nipload : Max 80kg/cm
Niploading: Hydraulic cylinder type
Nip relief : Air bellows type
Top and bottom both swimming roll child cost iron.
Middle Queen Roll is drive roll surface covered chilled cast iron.

REWINDER SECTION:
Type of rewind:
Horizontal 2 drum surface winder.
Unwind jumbo roll dia: 2200mm
Wind baby roll width: 3450mm
Winding baby roll dia: 1250
Winding baby roll width: 3400mm
Drive speed: 1800m/ min
Operating speed: 1600m/min
Max. Total web tension: 2700 N
Shaft less core shaft system,
Core size: 76mmID (106mmOD)
Tension control system: Load cell
Roll changing device: Kicking cradle and lowering system.

2.2.2 Paper Machine 02

paper machine -02 is a rebuilt high speed Fourdrinier fine paper , Linear, Medium, packaging & base
paper for coating paper machine.
Basis Weight range: 46-150 gm/ m2
Paper machine consists of Process approach flow system Dilution Head box, Wire part with twin wire,
suction couch, suction pick up, Combined press, Third press ,4th press, pre Dryer, Film size press,
Hard nip kuster calendar , reel section, re –realer , re- winder and quality control system. In press
section provided bottom swimming roll and 3rd swimming roll.

Approach flow system:pm-02

Pm- 01 and Pm-02 approach flow system is almost [Link]-02approch system addition extra dilution
White water header. From dilution water header (Fresh water tank) water goes to head box Deaerator
tank, dilution screen and then add head box.
Stock and dilution water ratio 80%:20%. Dulition water continuous recirculation, deaeration,
screening by head box dilution screen and add continues head box.
 16
Head box for Pm -02 (Voith dilution head box control system module)
Slice Width : 3800mm
Design Speed : 1000m/min (Max)
Total : 20-44m3/min
Header inlet: 41m3/min (Max)
Circulation: 3.0m3/min
Header Inlet : 7.2m3/min
Header Circulation 0.5m3/min
No. Of module jet unit: 59Pcs
Pit of unit : 64.8mm
Slice opening : 5-150mm
Operating Range : 10-30mm

FOURDRINIER SECTION:
Wire part is consists of top and bottom wire. Bottom wire carries 60-70% moisture and Top wire 30-40%. Top
wire drainage ratio 25-35%.Top wire having 3 Duo-D box chambers with sheet transfer box and top wire
cleaning box
Duo-D box main work to increase the drainage, cleaning box is used to clean the top wire and sheet trans box
transfer the paper web from top wire to bottom wire. In bottom wire having 4sets suction flat box. Bottom wire
use different angle blade.
. Press part: Press section comprises pick up roll, 1st press, 2nd press, 3rd press and 4th press.
Type of press: Tri Nip press and 4th press.
Vacuum Configuration: Vacuum configuration is almost same pm-01, pm-02 and my previous mill. Only
different controlling system. Here we are controlling by controller but earlier we control by manual valve.

DRYER SECTION:
Dryer section consists of pre dryer and post dryer. Out of 55 cylinder pre dryer contain 37cylinder and post
dryer 18. Multi cylinder with closed geared with each group sectional drive. Steam design pressure: 4.00kg/
cm2 and testing pressure 8.0kg/ cm2. Last cylinder having cooling water system but right now not provided
water incoming and outgoing system. Purpose of cooling cylinder is to improve smoothness of paper.
For all dryer cylinders’ steam supply and condensate discharge are executed on the drive side. Rotary siphon
and stationary siphon is fixed inside of the dryer cylinder. 1st dryer group dryer no: 03, 05 and 07 dryer is single
run dryer.
Total dryer section having hood exhaust fan, heat exchange, hot air blower and pocket ventilation system and
differential pressure etc.

Film size press:

Film size press is able to applying starch, pigments and color coating. The major benefits of the film size press
are lowering rewetting of paper and lower energy consumption in the post dryer section.
Film size press allows applying different formulation to each side of paper. That is a good sign of paper maker
to adopt the production to the requirements.

Calendar section:
We know the purpose of calendaring to modify the surface characteristics of the paper. These are mainly:
1)Gloss 2) Smoothness 3) Density 4) Brightness 6) Opacity.
Open frame, 4 stages, 3 nips calendar.
Nip load : 120 kg/ cm Max.
Nip loading : Air bellows type
Nip relief type: Air bellows type ( 2 sets) No 2 and No 3 roll
Composition of Calendar Roll:
1)Bottom and Top roll (2sets)swimming roll,
 17
2) 2nd bottom roll drive,
3)3rd roll middle roll, all rolls are chilled cast iron.
Swimming roll working principle:
Swimming roll can be applied variable load according to the paper property.

2.3Block diagram: Figure-1: Block Diagram of Stock Preparation

BBBBBLOCK

Block Diagram of Stock Preparation

 18
Figure-2 : Process Diagram of Fourdiner Paper Machine:

0
Figure: P & I Diagram of Stock Preparation
.
 23

Finishing Section:
They were working to complete the daily production. Two sheet cutter are installed in ground floor
and two sheet cutter installed in 1st floor. This sheet cutter capacity, speed and baby roll feeding
quantity mention bellow:

Sheet cutter no Feeding roll quantity Speed Capacity

01. 08Pcs 150-175mpm 56 MTPD
02. 08Pcs 180mpm 56MTPD
03. 07Pcs 100mpm 30MTPD
04. 08Pcs 160mpm 80MTPD

In finishing house there were two auto ream wrapper packing machine and two roll wrapper machine
installed. Auto ream wrapper packing machine going on but .Auto ream wrapper packing machine
marking MD/CD direction.

Delivery section:
Delivery section organized delivery by one manager with three executive and some stuff.
They make complete the total delivery program.

.
 24
Chapter-3
Material and Energy Balance

3.1: Material Balance:

Material balance on oven dry basis for 100 MT WWPP (white writing printing paper) Paper

Process Input:
Pulp (ADMT): 90 MT

Less 10% Moisture (90-10%) = 81 MT (OD)

System re-use broke 10%= 10 MT

Less 5% Moisture (10-5%) = 9.5 MT (OD)

Filler 12% = 12MT (OD)

Total system Input (OD) = (81+9.5+12) MT

= 102.5 MT

PROCESS OUTPUT:
Net output Production (ADMT) = 100 MT
5% Less Average Moisture (100-5%) = 95MT (OD)
Fiber recovery from process (ADMT) = 3.5 MT
= 3.325 MT ODMT
Sewer loss (ADMT) = 2 MT
Sewer loss (Solid) ODMT = (2-5%) = 1.90 MT

Total system Output (OD) = (95+3.325+1.90) MT

= 100.225MT

Total Input = 102.5 MT and Total Output = 100.225 MT

In paper manufacturing process Total In put = Total output physically not possible for materials balance.
 25
3.2: Energy balance for Paper process: The paper industry is one of the most capital and energy
intensive industries, where large amounts of energy such as steam and electricity are consumed during pulp
and paper making processes. It is therefore important to analyze the energy and exergy flow to identify the
potential areas where the energy efficiency can be improved.
There are Three- Phase modelling for the energy system in Papermaking Processes. There
are a lot of operation units in paper mills and each operation unit has its unique characteristics in terms of
energy conversion, use and recovery. Therefore, different functions of these operation units can be classified
into the same function phase. BMPIL is considered here which consists of Stock preparation and two
paper machines with a production capacity of 450,000 tons of papers per year.

1)Energy-conversion phase: Boiler, Steam etc.

2) Energy-use phase: Raw material preparation, cooking, bleaching, paper machine etc.

3) Energy-recovery phase: Condensate recovery, waste heat exhaust recovery in dryer section etc.

Figure 1: The paper mill three-phase model

 26
The energy and exergy balance of the paper mill is shown in Table II. From this table, it can be
seen that the total energy consumption in the paper mill is 317087.78 kW and the exergy
consumption is 341121.61kW. This indicates that the process energy consumption in the paper
mill is large.

Energy Measurement of the process:

Energy
Phases Item
Flow(kW)
Energy- Gas 470874.05
conversion Heat 14156.97
phase Recycled 110891.09
Energy
Heat
inputted
Steam 40263.57
Electricity 4670.06
Total 640855.74
Electricity exported 118300.46
Exported heat 94576.41
Ejection 242532.17
Exergy loss ——
Effective use 74555.61
Recycled 11431.27
Energy-use
Total use 85986.88
phase
Thermodynamics loss 4777.41
Exergy loss ——
Energy- For recovery 81209.47
recovery Export from recovery 9803.22
phase Recycle 11431.26
Ejection 59974.99
Exergy loss ——
Energy consumption 317087.78
Conversion efficiency 62.15
(%)
Total Recovery efficiency 26.15
(%)
Total ejection 302507.16
Total exergy loss ——
 27

Energy Flow chart:

Energy-usage phase analysis:

From Figure 2, it can be seen that the recycled energy is given by Er = 11431.27 kW and it is about
13% of the total energy-use phase. From the on-site data analysis it has been observed that the hood
exhaust fans were always running at a constant jaw opening. This means that the mill should control
the fan according to the changes of the ambient temperature so as to strengthen the hot air recycle.
In addition, analysis on other process data showed that the hood air leakage is about one third of the
in-take air and a correct control strategy should be employed.

Energy-recovery phase analysis

The energy recovery efficiency is 26.15％ and exergy recovery efficiency is 11.90%, both of them
are not desired .The ejection energy is 59974.99 kW and this is because the hood exhaust of one
paper machine temperature is 52 degrees which leads to much energy lost. Meanwhile, one paper
machine is too old and lack of condenser recovery equipment. Therefore, it needs to strengthen the
heat exchange to recycle more energy from the exhaust and also install some new condensers.
 28
Chapter-4
Cost Estimation

Table 4.1: Typical percentages of fixed-capital investment values for direct and indirect cost:
Component Range of FCI (%)

Direct costs
Purchased equipment 25-45%
Purchased equipment installation 6-8%
Instrumentation & controls (installed) 4-10%
Piping (installed) 4-10%
Electrical system (installed) 4-10%
Buildings (including services) 4-16%
Yard improvements 2-4%
Service facilities (installed) 8-20%
Land 2-5%
Indirect costs
Engineering & supervision 5-15%
Construction expenses 4-10%
Legal expenses 2-5%
Contractor’s fee 1-4%
Contingency 4-15%

Table 4.2 : Summary of purchased equipment cost for the BMPIL plant
Equipment Type Purchased Cost(TK)

Conveying system 2085700

TDR 658700
Motor 128700
Generator 650700
Pumps 806700
Boiler 805700
Heat exchangers and Condensers 403700
Blower 205700
Scanner 453700
HDC 305700
LDC 800700
Deflaker 204700
Pressure Screen 504700

Total 8015100
 29

4.3 Estimation of Total Product Cost

Section Percentage (%) Amount (TK)

Variable production cost

Raw materials 20% 18,00000

Operating labor 2% 1,80,000

Operating supervision 1% 90,000

Electricity 2% 1,80,000
Fuel 2% 1,80,000
Refrigeration 1% 90,000
Steam 2% 1,80,000
Waste treatment &
1% 90,000
disposal
Water, process 5% 5,500000
Water, cooling 1% 90,000

Maintenance and repairs 5% 4,50,0000

Royalties (if not on

1% 90,000
lump-sum basis)

Subtotal: 38,90000

Fixed charges

Depreciation 3% 2,70000
 30

Taxes(property) 1% 90,000
Financing (interest) 1% 90,000
Insurance 1% 90,000
Rent 2% 1,80,000

Subtotal 7,20,000

Plant overhead costs

Medical and Safety 2% 1,80,000

General plant overhead 1.5% 1,35,000
Payroll overhead 1% 90,000
Packaging 0.50% 45,000
Restaurant 1% 90,000
Recreation 1% 90,000
Salvage 1% 90,000
PLC Control license 2% 1,80,000
Plant superintendence 2% 1,80,000
Storage facilities 1% 90,000

Subtotal: 11,70000

Manufacturing cost = Total of variable production cost + Total of fixed charges + Total
of plant overhead costs

Total= 38,90000+7,20,000+11,70000

Total= 57,80000
 31

Administrative expenses

Executive salaries 8% 7,20000

Clerical wages 1% 90,000
Engineering 5% 4,50,000
Legal costs 1% 90,000
Office maintenance 1% 90,000
Communications 2% 1,80,000

Subtotal: 16,20000

Distribution and
marketing expenses

Sales offices 2% 1,80000

Sales personnel expenses 2% 1,80000
Shipping 2.82% 2,53,800
Advertising 5% 4,50000
Technical sales service 1% 90000

Subtotal: 11,50000

Research and
5% 4,50000
development (R&D)

General expenses = Total of administrative expenses + Total distribution and

marketing expenses + R&D

 32

= 16,20000 + 11,50000 + 4,50000

= 32,20000 TK

Total product cost = Manufacturing costs + General expenses

= 57,80000+ 32,20000

= 90,00000 TK
 33

Chapter 5
Safety and HAZOP
5.1 Industrial Safety
Industrial safety is the term consists of some precautionary measures that are observed by people at the
time of performing a job inside the factory with the help of some machine or equipment design in such
manner that can check the accident to be happened with ultimate view to achieve the possible higher
productivity.

5.1.1 Importance of Safety

The ultimate aim of safety is the complete prevention of personal injury, loss of life and destruction of
properties. Effective plant safety and fire protection are essential for every phase of operation and
maintenance of equipment & machines. Calculated risks must be reduced as far as possible. Equipment
& individual items must be examined time to time for normal service and also emergency demands.
Some major principles and practice of plant safety are mentioned below. For safe plant operation,
detailed safety instructions must always be established. All buildings, workshops, installation,
machinery and equipment must be furnished and maintains so as to protect the workers against accidents
and professional diseases. The instructions issued by the plant management for safe operation and for
the conduct of personnel must be followed strictly.

5.1.2 Responsibility of safety

The safety is of a preventive nature; the aim is to stop the risks and unsatisfactory conditions and their
incorporation into better working conditions. This requires contributions from and above all, co-
operation between both employees and employer.

5.2 General Safety Rules

The Bangladesh government established a general safety rule for industry called “Safety in the Factory
Rules, 1979”. Every industrial personnel is to observe the following general safety rules:
• Use appropriate personal protective apparel and equipment for the operation.

• Use alert to unsafe conditions and reactions. Call attention to hazards so the corrections can be
made immediately.

• Use laboratory equipment only for its designed purpose.

• Know the location of emergency equipment in your area. Read and become familiar with
emergency response procedures.

• Label all chemicals clearly and correctly.

• Avoid destructing or startling any co-worker in the laboratory. Practical jokes or any horseplay
cannot be tolerated at any time in the laboratory.
• Access to exits, emergency equipment, controls and such must never be blocked. Stairways and
hallways must not be used as storage areas even temporarily. 34

5.3 Safety Sign

For the concern of the company’s personnel safety, different safety signs are used such as:

Prohibition Sign
Example: No smoking, Pedestrians prohibited, No drinking water etc.

Warning Sign
Example: Risk of electrical shock, Laser beam, Risk of explosion, Risk of fire, Toxic hazard.

Mandatory Sign
Example: Eye protection, Hand, head and foot protection, Hearing and respiratory
protection etc.

.
 35

Safety equipments : The following equipments are used for safety consideration

Fig: Head protection gear

Fig: Leg protector Fig: Hand protector

 36

5.4 HAZOP Analysis

A hazard and operability study (HAZOP) is a structured and systematic examination of a complex
planned or existing process or operation in order to identify and evaluate problems that may represent
risks to personnel or equipment. The intention of performing a HAZOP is to review the design to pick
up design and engineering issues that may otherwise not have been found. The technique is based on
breaking the overall complex design of the process into a number of simpler sections called 'nodes'
which are then individually reviewed. It is carried out by a suitably experienced multi-disciplinary team
(HAZOP) during a series of meetings. The HAZOP technique is qualitative, and aims to stimulate the
imagination of participants to identify potential hazards and operability problems. Structure and
direction are given to the review process by applying standardized guide-word prompts to the review of
each node. The relevant international standard calls for team members to display 'intuition and good
judgment' and for the meetings to be held in 'a climate of positive thinking and frank discussion'.
The HAZOP technique was initially developed in the 1960s to analyze major chemical process systems
but has since been extended to other areas, including mining operations and other types of process
systems and other complex systems such as nuclear power plant operation and software development.
It is also used as the basis for reviewing Batch processes and operating procedures.
The method is applied to complex 'processes' for which sufficient design information is available, and
not likely to change significantly. This range of data should be explicitly identified and taken as the
‘design intent’ basis for the HAZOP study. For example, a prudent designer will have allowed for
foreseeable variations within the process creating a larger design envelope than just the basic
requirements and the HAZOP will be looking at ways in which this might not be sufficient.
For processes plant, the nodes are chosen so that for each a meaningful design intent can be specified
and they are commonly indicated on piping and instrumentation diagram (P&IDs) and process flow
diagram (PFD). The extent of each node should be appropriate to the complexity of the system and the
magnitude of the hazards it might pose. However, it will also need to balance between "too large and
complex" (fewer nodes, but the team members may not be able to consider issues within the whole node
at once) and "too small and simple" (many trivial and repetitive nodes, each of which has to be reviewed
independently and documented).
 39

Conclusion

It is one of the modern factory in Bangladesh which is operated by QCS system.. It is equipped with
latest technology, machineries and facilities. This factory maintains an effective administration,
securities and good labor management. So every year this factory fulfils the estimate production
capacity.

From this I have received a good concept on the latest technology of chemical process in this selective
field. In this report, I have tried my best to cover up all aspects of this plant including process chemistry
and operation, utilities, environmental pollution, safety aspects, economics etc.

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New York: McGraw hill Book Company, 1967.
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3. Grades of Paper, India, Edited by Santosh Swar
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5. Pulp and Paper Manufacturing 1 by LECTA.
6. Fundamental of Paper Making by Md. Delowar Hossain
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Timmerhaus, Ronald E. West; University of Colorado.
8. Perry's Chemical Engineering Handbook (7 ed.). (D. W. Green, & J. O. Maloney, Eds.) McGraw
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9. Chemistry of Modern Papermaking by Cornel Hagiopol James W. Johnston

10 J.M. Smith and H.C Van Ness. Introduction to Chemical Engineering Thermodynamics .Third
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Safety/[Link]
 40

14. Fire and Life Safety Compliance Guide. (2009, March). Retrieved June 14, 2013, from University
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[Link]

15. How to Interpret Piping and Instrumentation Diagrams. (2010, August 24). Retrieved May 22,
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16. Chang, J. I., & Lin, C.-C. (n.d.). A study of storage tank accidents. Journal of Loss Prevention in
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17. Chemical Engineering Plant Cost Index (averaged over year). (n.d.). Retrieved June 18, 2013, from
Norwegian University of Science and Technology:
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18. List of safety precautions for shutdown activities of chemical plants. (n.d.). Retrieved June 18,
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19. Lloyd, L. (2011). Handbook of Industrial Catalysts - Fundamental and Applied Catalysis. In
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