Plant and Machinery

Plant & Machinery

Name of Manufacturer

Year of Installation

Paper 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

Major Process Control Systems:

DCS 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

 

HNL is interested in the import substitution for the following:

  • Bearings
  • Paper machine clothing
  • Speciality chemicals

Prospective suppliers/ agents/ entrepreneurs may contact:

Mr John Mathews .HoD(Commercial )  at johnmathews@hnlonline.com

Raw Materials

Materials Required

  • Fibrous raw materials like wood, reed, bamboo etc.
  • Old Newspaper (ONP) and Old Magazines (OMG) for De-Inking Plant.
  • Chemicals used in pulp and paper making like caustic soda, hydrogen peroxide etc.
  • Packing materials like kraft paper, grey board etc.
  • Imported machineries and spares
  • General spares like motors, bearings etc.
  • Fuels like coal, furnace oil etc.
  • Paper machine clothing (felts, wires and screens)

Fibrous raw materials
HNL meets a major portion of its requirement for fibrous raw materials from forest sources. The credit for the superior quality of HNL newsprint goes to the unique raw material: Reed (Ochlandra travancorica) which is a specialty of Kerala forests.

The company has a long-term agreement with the Government of Kerala for the supply of Eucalyptus wood and Reed from state forests. Dwindling forest resources has led to this supply getting diminished in the past few years.

HNL has developed appropriate alternatives by :

  • Raising captive plantations using own resources and technical know-how on land allotted for that purpose by Govt. of Kerala, and also on vacant land made available by various institutions like Railways.
  • Encouraging pulp wood cultivation on agricultural land through implementation of farm forestry schemes.
  • Procuring raw materials from neighbouring states where they are available.
  • Buying Eucalyptus, Bamboo and other 'pulpable' raw materials from local suppliers and farmers directly under "Purchase at Gate" scheme.
  • Recycling of waste paper to manufacture pulp.

Chemicals and packing materials
HNL being a process industry, utilises a range of chemicals in the production process. The list of these chemicals and their annual requirements are as follows:


 

Chemicals
(Annual Requirement in MT)

Hydrogen Peroxide (50% concentration) 4,600
Soap Stone Powder(Talcum) 3,700
Caustic soda lye 4,300
Raw Lime Shell 7,000
Chlorine 725
Non-ferric Alum 1,700
Ferrous chloride ( for ETP) 19,000
Sodium Silicate 2,700
Sodium Sulphate 1,100
Sulphuric Acid 450
Hydrochloric Acid 150

 

Packing materials

Kraft paper 925
Grey Board 575

 

Energy
HNL has a 22 MW coal-based captive power generation facility. HNL requires a large amount of fuel and electricity for its production process.
 

Coal (indegenous & Imported) 0.15 million MT
Electricity (Purchased) 1050 lac Units
Furnace Oil 2500 Kilo litre.

 HNL is particular in procuring quality chemicals and other inputs as per specifications/norms.

For further information prospective suppliers / agents may kindly contact :
Mr. John Mathews A , Sr.Manager (Commercial ) at johnmathews@hnlonline.com

Process

Three grades of pulp:-Chemi Mechanical pulp,Chemical pulp and De-inked pulp are blended to manufacture newsprint.

 

Chemi Mechanical Pulp (CMP)
230 BDMT per day CMP plant (Sunds Defibrator, Sweden) uses hard wood(Eucalyptus,Acacia) chips to produce pulp. Chips are washed, presteamed and impregnated with caustic soda. Impregnated chips after recovering spent alkali 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. The TCF bleaching process operates effluent free. Bleached pulp after third stage refining is sent to High Density storage tower for onward use in paper machine.

 

Chemical Pulping (CP) 
Capacity of CP plant is 100 BDMT/day.
Reed/ Bamboo chips are pulped using conventional kraft process using stationary vertical Digesters of BHPV make. After counter current washing, pulp is bleached using chlorine followed by Hydrogen Peroxide stage.

 

De-Inking Plant (DIP)
The 100 TPD De-Inking Plant uses Old Newspaper (ONP) and Old Magazine Paper (OMG). Waste paper is weighed and pulped in Batch Pulper and stored in Dump Tower. Pulp is cleaned off the contaminants using HD cleaner followed by 2 stage hole screening. A seven cell floatation process removes the ink from pulp. Pulp is further cleaned in 4 stage centri-cleaners followed by 3 stage slot screens. Pulp is thickened in Disc filter and Screw Press to 30 % dryness and subjected to hot dispersion. Pulp is then bleached using Sodium Hydrosulfite 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.

 

Into Paper Machine
The CMP, CP and DIP are mixed in a definite ratio and supplied to the headbox through approach flow system wherein chemical additives are added. The paper machine approach flow system consists of four-stage centri-cleaner, Clark and Vicario Deculator system, primary fan pump and a variable speed secondary fan pump and pressure screens.

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 open calendar stack with two Kusters swimming rolls.

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.

The Utilities
The steam requirement is met by 3 ABV/ABL 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. About 35% of total power requirement is met through State Electricity Board. Also the mill has an effective water and air supply system for plant use and controls.

 

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.

Technology

HNL employs state-of-the-art technology and precision-driven processes to ensure that the end product is of superior quality. Some of the highlights are:

  • Continuous upgradation 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, with ERP and other supporting infrastructure networks – to ensure quick response time.
  • Online Digital quality control system.
  • Incremental, significant technological improvements in all critical areas like pulping, paper machine and finishing areas.

In the forefront
HNL has always maintained an edge in technology. Following are a few instances of the use of modem technology by HNL.

  • Used Hydrogen Peroxide for bleaching which resulted in better bleaching and lesser pollution.
  • Installed and later upgraded the computer based Quality Control System for Paper machine.
  • FBC conversion of Boilers.
  • Introduction of DCS 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 Fiber Optic LAN for mill-wide Computer networking.
  • Implemented Enterprise Resource Planning (ERP) software, BaaN for all business activitives.

 

Production Capacity

HNL has established itself as a leader in newsprint market with its superior operational efficiency with consistency in capacity utilization above 100% since 1990.

Fy 2016-2017 - Highlights:

Production 91831 MT
Capacity Utilization 91.83 %
Sales 95561 MT
Sales Turnover   Rs 337.94 Cr

Research & Development

R&D at Hindustan Newsprint Limited:
The in-house R&D at Hindustan Newsprint Limited is recognized by Department of Scientific and Industrial Research (DSIR), Ministry of Science & Technology, New Delhi in the year 1992. The R&D section is well equipped with sophisticated lab equipments. This has got the facilities to carryout R&D activities in the areas of

  • Pulping
  • Bleaching
  • Deinking
  • Paper making
  • Chemical recovery
  • Water treatment
  • Pollution control and
  • Relevant fields related to the above

R & D activities:
The R & D activities are carried out to:

  • Improve the product quality and productivity of the mill with the available resources.
  • Find out alternate raw materials to meet the shortage of conventional raw materials.
  • Use of more secondary fibres to conserve forest based raw materials.
  • Improvement processes, technologies & techniques.
  • Exploring the possibility of wastes into value added products.
  • Making newsprint manufacturing technology more environment friendly.

Product/process development jobs so far completed:

  • Change from three stage refining to two stage in chemimechanical pulp mill to save energy without compromising pulp quality.
  • Use of retention aid in Paper machine helps reduction in fluff and improvement in print quality in printing press.
  • Alkyl Ketene Dimer (AKD) is being used in process to reduce water absorbency of newsprint slightly to facilitate four colour printing on both sides.
  • Fatty acid soap, which is a common chemical for waste paper deinking has been successfully replaced by cost effective surfactants.
  • Development of pilot plant for making Calcium chloride from lime sludge has been initiated by  R&D .The pilot plant operation in making calcium chloride from lime sludge has been demonstrated successfully and this has been proved to be a viable option.
  • Studies revealed that the  Effective Residual Ink concentration (ERIC) in final Deinked  pulp (DIP) made from 100% Old Newspaper (ONP) is high and brightness is low in comparison to DIP made from ONP mixed with Old Magazine (OMG). It is inferred that a minimum of 10% OMG mixed with ONP helps to reduce the ERIC  and improve the pulp brightness.
  •  Based on R& D studies to reduce furnace oil consumption in Lime Reburning  Plant, woodfines are being added along with furnace oil. The cost of production of Product Lime reduced by Rs 430/MT because of reduction in furnace oil consumption.
  • From the existing pulp availability and achieving of the possible high brightness pulp in their respective pulp plant, writing and printing paper of Cream wove grade (75% ISO Brightness) is manufactured in paper machine with the pulp furnish of 22% Imported Hardwood sulphite pulp, 55% Own chemical pulp and 23% high brightness own deinked pulp.
  • It is found that The mechanical and optical stability of writing and printing paper is unaffected by adding 10-15% high brightness CMP pulp . This furnish is being implemented successfully.

Product / Process development jobs in hand:

  • Study on coal (imported+indigenous) and other solid fuels blend to optimize their thermal value.
  • Deinking effect on ageing of old newsprint.

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