AgriWaste Paper Industry
MAPUA INSTITUTE OF TECHNOLOGY
School of Chemical Engineering and Chemistry
MANUFACTURE OF BOND PAPER FROM CORN
STOVER
A Design Proposal Submitted in Partial Fulfillment of the Requirements for the Degree
of Science in Chemical Engineering
De Guzman, Andrea Mella B.
Esperanza, Jailene O.
Lomat, Rouselle Jade J.
Rescober, Elbenson P.
September 22, 2005
1
AgriWaste Paper Industry
ACKNOWLEDGEMENT
We would like to acknowledge and express our greatest indebt ness and gratitude to
the following people, whose without their support, this paper would have not been
accomplished.
To Engr. Winston Flora for entertaining our questions during consultations and for
supervising us throughout the accomplishment of this paper.
To all our families, for being our strength at times when we want to give up and for
being our inspirations to strive for the best.
To all our friends and classmates who have been very kind in lending some of their
references material.
To Manny and Winnie who have been very supportive and helpful to complete this
paper.
And most especially to the Lord Almighty for giving us the guidance and wisdom.
To all of you, we give our sincerest gratitude and love.
Andrea, Jailene, Jade, Elben
2
AgriWaste Paper Industry
Table of Contents
i
ii
INTRODUCTION
History of Pulp and Paper
Manufacturing in the Philippines
The Paper Industry Future
Paper- Uses and Applications
The Corn Production
The Corn Plant and its Type
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
1
2
3
3
4
4
5
EXECUTIVE SUMMARY
Name of the Company
Logo of the Company
Vision
Mission
Objectives of the Project
Statement of the Project
SWOT Analysis
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
7
7
7
7
7
8
8
9
MARKET STUDY
Product Description
Bond Paper
Name of the Product
Properties of the Product
Uses of the Product
Major Users of the Product
Product Distribution
Areas of Dispersion
Selling Price Analysis
Price of the Product
Target Market
Historical and Projected Demand
Analysis of Projected Demand
Market Share
Factors Affecting the Market
Marketing Plans and Programs
Marketing Strategies
Means of Transportation
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
10
10
10
10
10
11
11
11
12
12
13
13
13
15
15
17
18
18
19
TECHNICAL STUDY
Description of Raw Materials
Properties, Collection and Storage of
Corn Stovers
……………………………………………………………...
……………………………………………………………...
20
20
20
Letter of transmittal
Acknowledgement
……………………………………………………………...
3
AgriWaste Paper Industry
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
21
24
28
31
33
34
39
40
41
49
50
54
ORGANIZATIONAL AND FINANCIAL
STUDY
Organizational Chart
Job Description
Policies, Rules and Procedures
Organizational Chart
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
55
56
62
63
FINANCIAL STUDY
……………………………………………………………...
63
ENVIRONMENTAL STUDY
Wastewater Treatment Plant
Environmental Impact Assessment
Environmental Policy
Material Safety Data Sheet (MSDS) Of
Bond Paper
Recommendation
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
……………………………………………………………...
94
94
96
103
104
Chemical Requirements
Manufacturing Process
Stock Preparation
Material Balance Major Assumptions
Overall Material Balance Assumptions
Detailed Material Balance
Energy Balance
Process Flowchart
Equipment Specifications
Equipment Layout
Plant Description
Equipment Optimization
……………………………………………………………...
……………………………………………………………...
106
Appendices
LIST OF TABLES AND GRAPHS
…………………………………………
…………………………………………
…………………………………………
…………………………………………
…………………………………………
…………………………………………
…………………………………………
………………………………………….
Table 2.1 : Properties of Bond Paper
Table 2.2 : Price List of Some Market Competitors
Table 2.3 : Market Share Projection
Table 3.1 : Non-wood Plant Fiber Characteristics
Table 4.1 : Equipment Specifications
Table 4.2 : Equipment Optimization
Table 6.1 : Pre-operating Expense
4
10
12
16
21
21
41
5
63
AgriWaste Paper Industry
………………………………………….
………………………………………….
………………………………………….
………………………………………….
………………………………………….
………………………………………….
………………………………………….
………………………………………….
………………………………………….
………………………………………….
………………………………………….
………………………………………….
………………………………………….
………………………………………….
………………………………………….
………………………………………….
………………………………………….
………………………………………….
………………………………………….
………………………………………….
………………………………………….
………………………………………….
………………………………………….
………………………………………….
………………………………………….
………………………………………….
………………………………………….
……………………………………….....
………………………………………….
Table 6.2 : Pre-operating Salaries
Table 6.3 : Interim Interest Expense
Table 6.4 : Land and Building Cost
Table 6.5 : Taxes and Licenses
Table 6.6 : Office & Laboratory Supplies
Table 6.7 : Equipment Cost
Table 6.8 : Delivery Cost
Table 6.9 : Communication Consumption
Table 7.0 : Electricity Consumption
Table 7.1 : Salaries and Wages
Table 7.2 : Packaging Cost
Table 7.3 : Repair and Maintenance
Table 7.4 : Fuel Projection
Table 7.5 : Waste Water
Table 7.6 : Solid Waste
Table 7.7 : Water Projection
Table 7.8 : Electricity Projection
Table 7.9 : Price Inventory of Raw Material
Table 8.0 : Price Inventory of Finished Goods
Table 8.1 : Total Project Cost
Table 8.2 : Cost of Sales
Table 8.3 : Marketing and Administrative Expense
Table 8.4 : Balance Sheet
Table 8.5 : Breakeven
Table 8.6 : Cash Flow
Table 8.7 : Projected Income Statement
Table 8.8 : Rate of Return
Table 8.9 : Schedule of Amortization
Table 9.0 : Payback
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
83
84
85
86
87
88
89
90
91
92
93
LIST OF FIGURES
Figure 1: Logo of the Company
Figure 2: Product Distribution
Figure 3 : Historical Demand of Bond Paper
Figure 4: Projected Demand of Bond Paper
Figure 5 : Overall Material Balance
Figure 6 : Detailed Material Balance
Figure 7 : Equipment Pictures
Figure 8 : Location Map
Figure 9 : Organizational Chart
Figure 10: GANTT Chart
Figure 11: Equipment Layout
Figure 12: Plant Layout
………………………………………………..
………………………………………………..
………………………………………………..
………………………………………………..
………………………………………………..
………………………………………………..
………………………………………………..
………………………………………………..
………………………………………………..
………………………………………………..
………………………………………………..
………………………………………………..
5
7
11
14
14
33
34
41
50
55
63
49
52
AgriWaste Paper Industry
INTRODUCTION
Today’s world is undoubtedly the world of industrial development. The
Philippines in order to cope up with the growing world of science and technology
has joined in the race of stability and have created industrial plants and improved
within our country not only in the industrial centers but also in the less urban areas.
The growth of industries had created a demand for technical men and women
to design, construct, and operate industrial plant.
Through the research and
development programs, new technology of using alternative raw materials that are
less expensive but highly competitive to the world market specifically to the
exportation activities have been developed.
The pulp and paper industry plays a major role in the viewpoint of mass
communication, education and industrial economic growth. The art of paper making
is centuries old. Its development closely follows the trend of economic growth and
also population growth. On the other hand, the available environmental resource
depleted each year specifically the timber resources for the paper manufacture.
Thus, through some enormous research work several papermaking techniques
using agricultural residues such as bagasse, rice husk, jute sticks, grasses, corn
stovers etc. has given a clear view in the paper mill industry and now rapidly
becoming popular to be used as source of raw materials for papermaking.
The use of agricultural residues and other waste materials which are
traditionally thrown away or burnt are presently used and studied to prevent
degradation of the natural ecosystem, to reduce the load of fresh fibers from timber
resources, and also to reduce the waste disposal.
6
AgriWaste Paper Industry
HISTORY OF PULP AND PAPER MANUFACTURING IN THE PHILIPPINES 1
Before the 1930’s the Philippines imported paper from China, Spain (15651898), and the United States (1898-1946). The country did not have the market to
justify mass production of paper and its’ vast forests were believed unsuitable for
this purpose. The rapid development of the sugar industry and the advancement of
processes for bulk production from straw and bamboo, however, changed the trend
in the 1930’s.
In 1939, the Compania General de Tabacos de Filipinas organized Compania
de Cellulosa de Filipinas. The said company built the country’s first pulp and paper
mill, a 10 tons/day bleached paper mill at Bais, Negros Oriental, based on bagasse
from a sugar mill they controlled in this area (Central Azucarera de Bais). This mill
used the Pomilio process consisting of a mild caustic cook, chlorination with
gaseous chlorine, followed by a conventional bleaching system.
It now has a
capacity of 45 tons/day of bleached writing paper.
In 1950, the government-owned National Development Corporation brought in
a paper machine (20 tons/day) to produce cement bags from imported pulp. This
machine was later transferred to the APO Cement Corporation for the same purpose
and intermittently operated for a few years but was finally shutdown. In 1948, the
San Miguel Corporation started up the first paper corrugator in the country using
imported board.
The popularity of this packaging product immersed swiftly and
created a growing demand for containerboard.
Because of the deteriorating balance of payments position, the government
was forced to institute import controls in the late 1940’s, and these continued
through the 1950’s. Such controls encouraged the establishment of a number of
small paper mills operating on imported pulp or waste paper. The first of these was
the Philippine Paper Mills, Incorporation, which started in 1951 to produce chipboard
from waste paper.
In 1960, a group of local businessmen organized the Bataan Pulp and Paper
Mills, Incorporation, to build a pulp and paper mill based on bamboo. This mill, with
1
Scale Paper Making – International Labor Office Geneva, Technical Memorandum No. 8
7
AgriWaste Paper Industry
a capacity of 75 tons/day of bleaching writing paper started up in 1962 but ran into
serious problems with the supply of raw materials.
In 1950, Bislig Bay Lumber Company, Incorporation, began to operate a
timber concession on the eastern coast of the island Mindanao, which formed the
raw materials’ base for a large-scale pulp and paper mill. Bislig was confident that
the technology could be developed to use the short-fibred Philippine mahogany in
the manufacture of paper and was particularly interested in producing Kraft
Container board for use in the corrugated carton plant of San Miguel Brewery
Incorporation.
A research program was started on the use of Philippine woods for this
purpose. In 1953 Bislig Industries started to implement this project. Bislig Industries,
Incorporation is now known as the Paper Corporation of the Philippines.
In 1973, the United Pulp and Paper Company built an integrated pulp and
paper mill in Bulacan (Luzon) to produce 30930 tons/day of Kraft pulp for cement
bags. This mill uses bagasse pulp manufactured in its own pulp mills and imports
long fiber pulp.
The pulp and paper industry of the Philippines has been badly hit by the
previous recessions. Developed countries have repeatedly dumped paper into the
country at incredibly low prices, which has severely distressed local markets.
However, it can be expected that the pulp and paper industry of the
Philippines will survive the crisis and emerge in a more efficient and stronger
financial condition. Steps are being taken to increase the reserve of raw materials
through an extensive reforestation program, and the country is expected to become
a significant factor in the pulp and paper industry in Asia.
The Paper Industry Future
Education, literacy and industrial growth spur the demand for paper products.
The development of paper industry closely follows the trend of economic growth.
Therefore, as more income is realized in the country, paper consumption and
production are anticipated to rise. Taking into consideration the annual growth of the
8
AgriWaste Paper Industry
country’s population and favorable outlook for the economy, domestic demand for
paper and paper products will be on up trend in the coming years.
Paper- Uses and Applications2
Paper represents a commodity of day to day modern life. It is well known
item which, is only media of communication through writing. It has helped the men
from past in practicing to become literate and educated. It is considered as the most
important and right medium for education. Nowadays, use of paper of different
qualities has become very important in every field of modern life i.e. offices,
education institutes, research and engineering centers, art rooms, book printings,
magazine and newspaper publishing etc.
The Corn Production3
On a worldwide basis, corn is planted on approximately 325 million acres
(132 million hectares), with a harvest of more than 450 million metric tons (17.7
billion bushels; 624 billion liters). This annual harvest is second to wheat, by a
difference of less than 10 percent.
In industry, corn is used in the manufacture of a wide range of nonfood
products. Even the cornstalk and other plant parts have industrial uses. The stock is
processed into building materials, conditioners, paper, explosives, and packing
materials.
The cobs yield furfural, a raw material used in the manufacture of
plastics, nylon, and other materials. The husks are widely used as fillers, and their
tender inner parts are boiled to sugar and then pressed and dried to make cigarette
paper.
2
3
Handbook on Pulp and Paper Industries -SIRI Board of Consultants and Engineers
Colliers Encyclopedia, Volume 7 c.1996 by P.F. Collier and Sons Limited, U.S.A. p.333
9
AgriWaste Paper Industry
The Corn Plant and its Type4
The corn plant has a jointed stalk varying in height from 2 to 20 feet (0.6-6
meters) and in diameter from one half inch to 2 inches (1.3-5 cm). At the base of
each stalk, or internode, are buds that produce lateral branches called ear shoots.
These ear shoots may develop into ears of corn. The leaf consists of the blade, the
sheath, and a collar-like ligules. The leaf blade tapers from the central midrib to the
edges and also to a point at the leaf tip.
The development of the pulp and paper industry closely follows the trend of
economic growth.
Therefore, a small income is realized in the country, paper
consumption and production are anticipated to rise. Taking into account the 2.4 %
average annual growth of the country’s population and the favorable outlook of the
economy, domestic demand for paper and paper products will be on the uptrend in
the coming years.
It is unfortunate though those because of frequent breakdown obsolete plant
equipment, domestic production has not been able to meet rising demand. It only
accounts for 6.5 % of the supply of pulp and paper were the balance is satisfied
through input. If the industry desires to reduce input dependence and conserve
scarce foreign exchange, players would have to invest in new facilities the face of
the challenge of improving product quality and cost competitiveness.
Corn varies in different types. Dent corn is the principal type grown in the
Corn Belt. Flint Corn has no dent or depression in the top of the kernel, and the
endosperm is almost all hard starch. The group is grown primarily in the Northern
United States where it is suited to the shorter growing season because of its earlier
maturity.
Popcorn is a type of flint corn with small kernels that have the property of
bursting when heat is applied. The bursting occurs because of the rapid expansion
of the starch endosperm. In the United States, popcorn is raised in Illinois, Indiana,
Iowa, Kentucky, Nebraska, and Ohio. Flour Sour has no dent in the top of the
kernel, and the endosperm is all soft starch. Because of the soft starch, the kernel
4
Colliers Encyclopedia, Volume 7 c.1996 by P.F. Collier and Sons Limited, U.S.A. p.334
10
AgriWaste Paper Industry
grinds into flour easily.
Flour corn is grown in many of the Central and South
American countries. In sweet corn the endosperm contains dextrin, a sugar-like
substance, with a lesser proportion of starch than the endosperm of other groups of
corn. The kernel may be more or less wrinkled when ripe, depending upon the
stage of maturity when harvested.
11
AgriWaste Paper Industry
EXECUTIVE SUMMARY
NAME OF THE COMPANY
AGRIWASTE PAPER INDUSTRY
AgriWaste Paper Industry is the name chosen for our company simply
because we are producing a quality bond paper product through the utilization of
agricultural waste such as corn stovers.
LOGO OF THE COMPANY
Figure 1.Logo of the Company
The circle represents our objective to become globally competitive in the
market; the corn plant symbolizes our main raw material. The color green represents
our objective to become an environment friendly industry.
VISION
The company shall be recognized as a world class manufacturer of quality
bond paper using global technology with local expertise.
It shall be known as
industry leader not only in the production of quality bond paper and other paper
products but also to the development of creative and innovative people as well.
MISSION
AgriWaste Paper Industry is fully committed to produce bond paper of high
quality and standards cheaper compared to imported bond papers, by providing the
needs of local industries and foreign and to contribute to the improvement of in the
commercial and industrial segments of the society.
12
AgriWaste Paper Industry
OBJECTVES OF THE PROJECT
This study aims to design a small-scale process of paper plant that will
manufacture, produce and sell paper product which is bond paper from agricultural
waste. The company’s project expects to achieve the following objectives:
To be known as the leading manufacturer of quality paper in the
Philippines and also in the world market by providing good quality of bond
paper at low cost to our economy.
.Aims to help in minimizing the waste produced by the agricultural
products such as corn through using the corn stovers as our main source
of pulp.
Aims to necessitate and support the increasing demand of bond paper in
local and global market.
Aims to minimize the importation of bond paper by increasing 7% of our
production every five years.
Aims to help improve the economic status of Santiago City, Isabela and its
neighboring towns and cities by providing additional employment.
STATEMENT OF THE PROJECT
The following statements represent the overall purpose of the company:
To manufacture, distribute, and sell, ready at all times to increase and
improve the production to meet the changes in market demand.
To provide significant contribution to the country’s profit income.
To satisfactory create revenue that will ensure an adequate company
growth rate.
To maintain the highest ethical standards in the conduct of the business.
To facilitate both personal and professional development of the
employees.
To be socially responsible.
13
AgriWaste Paper Industry
SWOT ANALYSIS
Strength
Production of quality bond paper at low cost / moderately priced
On time delivery
Provide employment
Utilize agri-based waste, particularly corn stovers
New breed of entrepreneurs
Customers/clients are
always
satisfied; we
exceed
customers
satisfaction
Support the government in their aim to uplift the economic situation
Weakness
Not well-verse in the field of business
(Shifts to strength is by hiring experienced people in the
business field)
Opportunities
Increasing Demand/High demand for bond paper
Welcome new investors
Open to new trend and market
Welcomes sponsoring project
Availability of a cheaper but of better quality of paper
New development/techniques and technology
Tough competition in the market
The emergence of the imported paper and thin competitive products in
Threats
the field of printing and writing
Peso devaluation – the decline or peso is a great effect in our
company’s profit and other aspects as well, since our equipment will be
imported from other countries.
(Shifts to opportunities is by maintaining good
quality of the product and having lower price that will be an advantage)
14
AgriWaste Paper Industry
MARKET STUDY
PRODUCT DESCRIPTION
Bond Paper
All types of paper are made from pulp containing fibers that form a matted or
felted sheet on a screen when moisture is removed. Nearly all paper is made up of
cellulosed fibers. The bond paper product we will be manufacturing was made from
agricultural fibers of corn stalks (stovers).
1. Name of the Product
AgriWaste Superior Bond Paper
2. Properties of the Product
The bond paper produced would be a bleached and sized paper that is
suitable for writing, printing and other graphic purposes. Some of the characteristics
of our bond paper are its good strength and durability in repeated handling, sized so
as to the prevent spreading of writing ink and render the paper more resistant to
moisture, and bleached so as to improve brightness and clarity. It has also a good
surface quality and erasability.
Table 2.1 Properties of Bond Paper Product
Substrate Type: superior bond paper
Weight
Size
Opacity
Smoothness(BEKK,
sec)
Caliper
Brightness (%,
min.)
160gsm (43lb.) Tint (Lab)
8.5” x 11”
Gloss
>90%
Environmental
Use
45-55
45-55
Storage
Conditions
(boxed)
92
15
93.5, 3.0, –7.0
n/a
15ºC–25ºC (59°F–
77°F),
30–70% RH noncondensing
10ºC–30ºC (50°F–
86°F),
10–80% RH noncondensing
AgriWaste Paper Industry
3. Uses of the Product
The use of the product is for writing, printing and other graphic purposes
which, is characterized to have a good product quality with affordable price.
4. Major Users of the Product
Schools (Private and Public)
Companies/Offices (Private and Public)
Bookstores
5. Product Distribution
The diagram represents the flow of our product distribution to our target
customers.
Process Plant
Warehouse
Marketing
Wholesaler
Bookstores
Commission Agent
Schools
( Private & Public)
Final Consumers
Figure 2.Product distribution
16
Companies/Offices
( Public & Private)
AgriWaste Paper Industry
6. Areas of Dispersion
AgriWaste Paper Industry will be located at Santiago City, Isabela. The bond
paper products will be distributed mostly in public and private companies and public
and private schools, bookstores within the area of Santiago City, and nearby towns
and cities in the Isabela province. Nearby provinces will also be of great interest.
SELLING PRICE ANALYSIS
Establishing a new business means you have to be very competitive in all
areas: quality, economically friendly and an affordable and reasonable price for the
consumer.
To decide the best price for the product, the sales team must know the
competitor’s price if the company can lower or meet the competitors pricing without
sacrificing the quality rendered to the product produce. In order for us to determine
the price of our product, we collected the price list of our major competitors if we can
meet their price.
Table 2.2 Price List of Some Market Competitors5
5
Brand Name of Our Major Competitors
Price / ream (500 pieces)
Best Buy
163. 75
St. James
190.00
Corona
225.00
Advance
200.00
Sterling
210.50
Prices are based on National Bookstores
17
AgriWaste Paper Industry
Aside from collecting our competitors’ price list, we also considered the
following aspects:
Government rules and regulations on price hike
Taxes rendered to our government
Product advertisements and promotions
Comparison of our products to our competitors
Considering the said factors, we have come up that our price per kg will be
Php37.62/kg. Our product will be competitive with the other commercialized quality
bond papers in the market today.
1. Price of the Product
The company’s bond paper production would be 6,062,654 reams per year
and increase of production every five years. The main raw material which is corn
stovers will be obtained free from the farmers but we will be paying for the labor of
collecting the corn stovers for us. The input corn stovers would be 100% and the
selling price of our product will be Php85.02/ream of bond paper.
2. Target Market
The target market of our company will be the fundamental users of our
products
which
consist
of
schools,
companies/offices,
printing/publishing
corporations and other that needs high quality and at low cost bond paper.
HISTORICAL AND PROJECTED DEMAND
AgriWaste Paper Industry will be producing bond paper for the first 10 years.
As the company celebrates its 10 years of operation, other kinds of paper such as
newsprint, onion paper and board paper will be proposed to produce. Importation of
the product will be done to meet the demand of Cagayan Valley Region consumers.
18
AgriWaste Paper Industry
From the Historical and Projected demand, almost 2% of the nationwide consumers
are from Isabela Province.
HISTORICAL DEMAND
Thousands
DEMAND(MT/Year)
900
800
700
600
500
400
300
200
100
1995
1996
1997
1998
1999
2000
2001
2002
2003
Year
Figure 3. Historical Demand of Bond Paper
D em and
(M illion R eam s)
PROJECTED DEMAND
700
600
500
400
300
200
100
0
2006
2008
2010
2012
Year
Figure 4. Projected Demand of Bond Paper
19
2014
2016
2004
AgriWaste Paper Industry
Analysis of Projected Demand
Based on the data gathered, there is an existing demand for bond paper.
Using the population (see Appendix A) growth rate, an optimistic projected demand
should be expected. Supply is based mainly on local production, which shows a
very healthy pattern of growth in the consumption.
The graph shows a steady increase of projected demand within ten years.
The positive outlook of the graphical projections can be justified by the influence of
the general economic progress of the country, degree of personal disposable
income, population growth, and price competitiveness of accessible paper as
compared to international standards. With the annual increase in demand, there is a
need to step up production to satisfy consumers.
Technical Feasibility
The working process is continuous due to the demand of paper in the
Philippines. The operation will be 24 hours a day and seven times a week. To
ensure the correct implementation of the plant procedure, the company will employ
highly qualified personnel and research workers.
MARKET SHARE
The assumed market share of AgriWaste Paper Industry, as a pioneer of corn
stover bond paper, will be 1.6% of the total Philippine bond paper market in 2007.
After five years of continuous supply, the company will increase its production by 7%
of the year 2011 and another 7% in the year 2016 total bond paper demand
20
AgriWaste Paper Industry
Table 2.3 Market Share Projection
MARKET SHARE
Sales
Year
Population
Phil. (ages
4-69)
Consumption
(pcs
paper/personyear)
Demand
(pcs/
person/year)
Demand
(MT /
Year)
(MT/Year)
2007
75179054
2555
192082481809
868,213
12,559.35
0.0145
2008
76656012
2555
195856109499
885,270
13,701.11
0.0155
2009
78132970
2555
199629737189
902,326
13,701.11
0.0152
2010
79609928
2555
203403364879
919,383
13,701.11
0.0149
2011
81086886
2555
207176992569
936,440
14,660.19
0.0157
2012
82563844
2555
210950620259
953,497
14,660.19
0.0154
2013
84040802
2555
214724247949
970,554
14,660.19
0.0151
2014
85517760
2555
218497875639
987,610
14,660.19
0.0148
2015
86994718
2555
222271503329
1,004,667
14,660.19
0.0146
2016
88471676
2555
226045131019
1,021,724
15,619.27
0.0153
Sources of population: National Statistics Office (NSO)
21
Market
Share
AgriWaste Paper Industry
FACTORS AFFECTING THE MARKET
The following factors may affect the industry market:
Population Growth
The increase in population greatly affects the market of bond paper since the
demand greatly follows the trend of the increasing population. Therefore, there
would be a greater demand for our bond paper products which means there would
be also a step up in our production.
Improved Technology
The significant technological improvements such as the use of electronic
mails in the business transactions of the companies/offices can decline the
demand of bond paper.
On the other hand, with the knowledge on advancement in the technology we
can also improve our company’s process/production which can help us to produce
a better quality and more products to produce.
Emergence of New Competitors
The emergence of new competitors can affect the market of the product since
people have the tendency to compare our bond paper product produced with our
competitors in the market. To ensure the customers trusts, we will produce the
best quality bond paper at lower costs and also establish an effective quality
management system and environmental management systems.
High Costs of Fuel and Energy
Among of the largest cost components in papermaking are its electrical
energy and fuel energy.
On the average, they constitute about 25-30% total
production costs for local paper manufacturer.
Protecting the Industry
Protection for domestic pulp and paper industry are either direct or indirect.
Imported Machineries and Spare Parts
Taxes and duties of machinery, equipment and spare parts not produced
locally should be kept at minimum levels.
22
AgriWaste Paper Industry
MARKETING PLANS AND PROGRAMS
The following marketing plans will guide our company all throughout the
operation:
Selection of major market or product areas for growth and profit
improvement.
Evaluation of market and competitive situation in each selected areas.
Establishments of goals for each area selected.
Determination of the possible strategies to achieve goals.
Implementation of strategies to achieve through plans that conclude
specific programs, completion dates and responsibility assignments.
Aggressive goal centered leadership plan measurements and control
of progress to achieve goal.
Plans to expand its operation by producing book paper in next 15th
year of operation.
MARKETING STRATEGIES
The following strategies will be done to be able to become competitive to the
market:
Product Launching
The product will be launched in the Isabela province which will be developed
by prominent people whose expertise in paper producing technology is of top
caliber.
Conduction of Seminars
Seminars with respect to the bond paper products will be conducted. The
seminar will focus on the Pros and Cons of our products as well as the company
performance.
It also includes some seminars for educational purposes of the
employees.
23
AgriWaste Paper Industry
Distribution of Leaflets and Brochures
Leaflets and brochures will be distributed to large and small users of the
product to ensure knowledge with regards to the quality and price of our product and
also to be able to promote and at the same time advertise our product.
Implementing Bulk Promotion
The company will implement a bulk promotion for our customers. They will be
entitled with great discounts if they will order in large quantities.
Direct Selling Approach
The direct selling of our product will be done through personally meeting the
clients in their respective offices and ask them if possible they will allow us to test
the quality of our product and if they will be satisfied, purchasing will be possible.
Internet Address
Information regarding our product will be available though our website.
MEANS OF TRANSPORTATION
Large Trucks (6-wheeler trucks) are the ones that we will be using to collect
corn stovers in the farm. Our company will be having its own trucks for such activity.
However, if in any case our trucks will not be available (due to motor failure, flat
tires), we plan to contract trucking establishment so that the activity will not be
cancelled or delayed.
For delivering our finished product (bond paper), the company will have
smaller trucks called Isuzu-elf. The main reason for having an “elf truck” is for the
accessibility of passing the narrow roads.
Also in several places in our target
provinces, market places (where dry and wet goods are sold) are not accessible by
huge trucks. Thus, we have to use elf to reach our prospective buyers.
In transporting the bond paper to our valued client is dependent of the
location or site of our target customers. The company will deliver the product within
one week after the placement of order by the customers. In case of exportation, the
product is transported through ships contacted by the company.
24
AgriWaste Paper Industry
TECHNICAL STUDY
DESCRIPTION OF RAW MATERIALS
The production of paper is for most part concentrated in areas that have
abundant supply of fibrous raw materials especially wood but in our case agricultural
waste such as corn stalks (stovers) would be in abundant.
A. Properties, Collection and Storage of Corn Stovers
Corn stalks (stovers), like straws, would probably be harvested in a time
frame consistent with the harvest of the grain, depending on specific harvesting
methods. The harvest of corn is usually twice a year but other provinces can raise
corn all year round.
During rainy season months of July to September the
production supply is minimal. Thus, during its peak harvesting months of summer,
collection of corn stovers must be made so that the amount of raw needed is met.
The storage room must be kept clean and the management must keep
the cleanliness of the area, avoiding personnel smoking around the premises
because it is fire friendly and also to avoid cases such as fire burning.
The bulk density of corn stovers is 0.7216. The theoretical ultimate strength of
primary valence chains of cellulose is calculated as 800 to 2260 kg/mm2, however
the ideal values approaches 100 kg/mm2. Thus, it is just appropriate to estimate that
we can stock corn stovers for as high as 20 meters in height and as many as 2000
cubic meters in volume is acceptable.
Corn stalks (stovers) cellulose content (35-45%5) ranges significantly
depending on variety and regional conditions and a pulp yields of 30-40%.7
6
7
Bulk density is http.www.denscs.com/cornstalk.com
Rymsza, Thomas A., “Agricultural Residues in Pulp and Paper Discussion Paper”
25
AgriWaste Paper Industry
Table 3.1 Non-wood Plant Fiber Characteristics8
Fiber Source
Fiber dimensions of various non-woods
Length (microns)
Diameter (microns)
Max
Min
Ave
Max
Min
Ave
Corn Stalks (Stovers)
2800
680
1260
20
10
16
L/D
Ratio
8:01
B. Chemical Requirements
1. Powdered alum
Alum is the common name for aluminum sulphate. Technically, the term
should be restricted to one of the double salts of aluminum sulphate and alkali
sulphate, such as potassium aluminum sulphate, K2SO4Al2(SO4)324H2O, which
originally was used in paper making because it was the purest form of alum. Alum is
soluble in water and is generally used in solutions containing from 2 to 3.5 lb. per
gal. The iron-free alum is use for the best grades of paper.9
Alum is usually added to correct the pH value. It is added to the paper stock
in order to increase its acidity to approximately pH 5. It is essential additive for good
refining adequate sizing, or rosin dispersion. It is also affects press performance by
reducing the tendency of paper to adhere to the top press roll.
It is commonly supplied in solid block form, but should be dissolved in water
and used in liquid form at a constant density. This chemical is also used for water
treatment in order to induce flocculation. Average consumption is 5 to 8 percent by
weight of the final product (bond paper).10
8
Hurter, Robert W., “Agricultural Residues”, TAPPI 1997 Non-wood Fibers Short Course &
Hurter, A.M., “Utilization of Annual Plants and Agricultural Residues for the Production of Pulp and
Paper”, Non-wood Plant Fiber Pulping Progress Report #19, TAPPI Press, pp. 49-70
9
http://www.perigee.net/~jrjohns/aluma.html
10
Handbook on Pulp and Paper Industries-SIRI Board of Consultants and Engineers
26
AgriWaste Paper Industry
2. Rosin
Rosin is water-repellent substance obtained from the gum (oleoresin) of the
southern pine, chiefly from the long leaf species. It is available in solid form and it
must be brought to a liquid emulsion before use. When it is distilled from the gum
that exudes from the living tree, it is called gum resin. However, when it is extracted
from the pine-stump wood or other resinous wood by the steam and solvent process
it is known as wood rosin.11
Rosin has a very low melting point and it is good sizing agent; contains 90%
resin acid (abietic acid) and 10% neutral material. It is also susceptible to chemical
or physical treatment that will make it readily soluble or mixable in water. It improves
printing or writing properties by controlling ink penetration.
The average
consumption is proportional to the consumption of alum.12
3. Sodium Hydroxide (Caustic Soda)
It is used in the manufacture of many organic and inorganic compounds, also
in soap making, paper making, rayon, detergents; in refining petroleum and
vegetable oils; and in reclaiming rubber. NaOH is prepared by the electrolysis of
aqueous NaCl and KCl solutions and it is a strong base and very soluble in water.13
Sodium Hydroxide is extensively used as a cooking chemical in paper mills. It
is available in solid form and also in liquid form at 50% concentration. The amount
of sodium hydroxide varies according to raw materials used.
For cotton linters,
jutes, etc. caustic soda is used around 5% of the total raw materials and for rice
straw and bagasse around 12 to 14%.ε
11
http://www.wikipedia.com.wiki/rosin
Handbook on Pulp and Paper Industries-SIRI Board of Consultants and Engineers
13
http://encyclopedia.thefreedictionary.com/Sodium+hydroxide
ε
Handbook on Pulp and Paper Industries-SIRI Board of Consultants and Engineers
12
27
AgriWaste Paper Industry
4. Sodium Hypochlorite
Sodium Hypochlorite is the preferred method of shock treatment because it is
readily soluble and rapidly increases the free chlorine content of the water. Just as
importantly the chlorine level drops quickly, especially in strong sunlight, to a level in
which bathers can return into the water.
Sodium Hypochlorite is ideal for shock dosing as it is a strong oxidizing agent.
This enables it to destroy combined chlorines, the source of irritation and odor
complaints. Sodium Hypochlorite contains 65% available chlorine.14
Sodium Hypochlorite is usually used as a bleaching agent in paper pants. The
purpose of sodium hypochlorite in bleaching the pulp is to convert the lignin in the
pulp to compounds that are soluble in water or alkali. It is used to obtain better color
stability and to reduce the viscosity of the cellulose for the case of dissolving pulp.15
5. Starch
Starch is used to improve the quality of writing and printing papers or the
stiffness of water-based corrugating medium. It is most effectively applied, in liquid
form at about 30 to 40 % concentration, to the surface of the paper through a size
press. More often starch can also be used in a less effective manner as an additive
to paper stock. It is also added to give firmness, stiffness, and strength particularly
to the surface of the sheet.16
Starch must be cooked and prepared in liquid form before use. Ready prepared starch is available and used extensively in developed countries but is not
likely to be used by the small mill in developing countries.
Starch requirement ranges from 3 to 12 percent by weight of paper,
depending on the quality to be achieved. 17
6. Talc
14
http://encyclopedia.thefreedictionary.com/Sodium+Hypochlorite
Handbook on Pulp and Paper Industries-SIRI Board of Consultants and Engineers
16
http://www.lsbu.ac.uk/water/hysta.html
17
Handbook on Pulp and Paper Industries-SIRI Board of Consultants and Engineers
15
28
AgriWaste Paper Industry
Talc is hydrated magnesium silicate. It serves as a substitute for clay in
similar proportions. It improves the opacity, brightness, and finish of writing and
printing papers. The amount required ranges from 10 to 15% by weight of the
paper.18
MANUFACTURING PROCESS
Paper is a sheet of interlaced fibers – usually cellulose fibers from plants that
are formed by pulping the fibers and causing them to felt, to mat, to form a solid
surface. Paper is said to be of high quality when the pulp used is of good quality
composed primarily of cellulose fibers.
Papermaking is a continuous process, an unbroken line of production that
begins with wood or non-wood fibers (such as of corn stovers) and ends with the cut
sheet of paper.
The lignin, the material that holds corn stovers cells is dissolved, and the
cellulose fibers are to be separated primarily because it is very complex and causes
color reaction with age. Chemical process is usually done in the pulping process
which was used to remove the lignin content of the non-wood fibers, and the
chemical solution consists of caustic soda is digested through a digester. Cooking
time may be as long as 2 to 3 hours depending on the recovery potential of the raw
material and the pulp characteristics. Therefore, we can say that pulping is the most
meticulous process in papermaking because it is the primary component of our
product – paper. If chemical pulping stages are wrong, the manufacturer will not be
able to produce quality paper products. Thus, we will concentrate primarily on the
chemical pulping processing stage.
FIBER PREPARATION
18
Handbook on Pulp and Paper Industries-SIRI Board of Consultants and Engineers
29
AgriWaste Paper Industry
Corn Stover Preparation
From the warehouse house, the corn stovers will be transported using forklift
and then be loaded manually into the mouth of the shedder and shredded to a
uniform length and transferred to though belt conveyor in the duster to be dusted
before loading into the digester. The removal of dust is record in order to ensure
good pulp quality; dust losses of around 0.3 % will be expected. The stovers will be
cut into pieces for 20 to 30 mm. long in order to facilitate the flowing of the chopped,
dusted stovers will then be transferred to the digester through an elevated belt
conveyor.
PULPING STAGE
Digestion
In the digestion process, it consists of cooking the prepared material in the
presence of sodium hydroxide (caustic soda) to isolate the cellulose fiber from the
lignin and other constituents of the corn stovers without causing much damage to
the fibers. Lignin acts as the binding materials and non-fibrous in character and
therefore must be eliminated in the process. Various pulping chemicals are used to
dissolve the lignin selectively and separate the fibers. In chemical pulping, the lignin
and other impurities are removed.
The materials in the continuous digester are screw-propelled through the
cooking zone because stringy vegetable materials do not flow naturally and
mechanical propulsion is therefore required to ensure constant feed.19
The process begins when the prepared corn stovers are loaded into the
digester through conveyors. The cooking of corn stovers chips is carried out at
temperatures of 170 degree Celsius and 0.4 MPa in the digester at 12% caustic
19
J. Newell Stephenson, “Pulp and Paper Manufacture, Volume 2”, c.1951, Joint Executive
Committee of Vocational Education Committees of the Pulp and Paper Industries, USA, 1951.
30
AgriWaste Paper Industry
soda solution (white liquor)20. A boiler is used to supply steam for the digester. The
proportion of caustic soda solution to pulp will be 1:4. Caustic soda consumption for
corn stovers pulping amounted to 12 percent by weight of bone-dry stovers input.
During the cooking process, the lignin and some hemi-cellulose molecules of the
corn stovers are break into smaller ones. After sometime, the lignin and hemicellulose contents have been removed. The charging liquor which is made up from
the caustic solution, some returned spent cooking liquor (termed “black” liquor”) and
hot water. The white liquor turned to black due to the dissolved impurities.
Blow tank
After cooking, the content of the digester is discharged through a valve at the
bottom of the digester. The pulp is transported through pipes using pumps, next,
transferred into the towering blow tank. The stock enters tangentially at such high
speed that it hugs the wall of the separator while the steam escapes to the center
and out through the ventilator. The pulp softened by the cooking process smashed
to the walls of the blow tank.
On blowing the charge the sudden release of pressure causes violent
evolution of steam from the moisture in the chips, and this, together with the
mechanical action of passing through the pipe, causes complete disintegration into
the fibrous state. The separator is usually placed at an elevation higher than the top
of the digesters and the stock therefore drops by gravity to the washing equipment.
At this point it contains the fiber, all the alkali originally added, the organic matter
dissolved during the cook, and a large amount of water, both from the liquor added
and from condensed steam.
20
J. Newell Stephenson, “Preparation and treatment of Wood Pulp”, Mc Graw Hill Book Company
Inc., New York, 1950.
31
AgriWaste Paper Industry
Washing
From the blow tank, the pulp and accompanying black liquor is usually
coarse-screened in order to remove uncooked particles (or shives), which should not
exceed 5 percent of the mixture. The rejects can be either returned to the digester
for further cooking or mechanically processed to an acceptable condition by
“refining”.
However, for mills of very small capacity the quantity of rejects is
insufficient to justify investments in a refiner. In order to obtain good quality pulp, a
three stage, counter-flow washing is used.
This procedure should also reduce
chemical losses if the mill is equipped with a chemical recovery unit.
Washers are open surface cylinders, covered with a wire mesh and rotating in
vats. The unwashed pulp is fed to the vat and picked up by the cylinder. The liquor
is drained away through the surface wire-mesh. The black liquor drained from the
first washer contains all the non-cellulose matter and chemical residues removed
from the pulp. It is passed to a filtrate tank for disposal or chemical recovery except
for a fraction, which is used for the making of the cooking liquor supplied to the
digester.
Washers can be either very simple and inexpensive or somewhat complicated
and costly but more effective. The most satisfactory units operate under vacuum and
require a special construction. Drainage is, in this case, improved and the on-going
pulp contains less chemical or organic impurities. Washers used in small mills can
be elevated in order to achieve the vacuum required barometrically. This procedure
reduces capital costs and power consumption.
Washing is necessary to prevent undesirable matter goes forward with the
pulp and adversely affects the bleaching quality and, ultimately, the quality of the
paper produced.
32
AgriWaste Paper Industry
Screening
The consistency of pulp leaving the washers varies, depending on the
effectiveness of the washer. The next stage is screening in order to remove particles
unsuitable for the paper process.
Also, the extra water was removed before the
bleaching process proceeds to ensure that the available chlorine in sodium
hypochlorite will immediately used in the pulp.
There are several types of screens suitable for small mills. However, the best
types are fully enclosed pressurized or centrifugal screens. After screening, the pulp
is ready for the bleaching process.
STOCK PREPARATION
Stock is treated in a beater or a refiner to give it desired characteristics for
paper formation. In a common type of beater, the fibers are mixed and pounded
between a large metal drum and a bed plate along the bottom of the beater. Beating
shortens the fibers and causes them to swell and fibrillate (fray along the sides and
at the ends). Beaten fibers form a tighter bond, and therefore a stronger paper, than
fibers that have not been beaten.
Bleaching
Bleaching is normally carried out on a three-stage basis. However, very small
mills may operate with a single-stage bleaching only. The bleaching process
removes the residual non-cellulose material from the pulp since it cannot be
removed by cooking without a lowering of both pulp quality and yield. Chemical
grade pulp contains 3-5% lignin. The residual lignin and other matters left on the
fibers caused the dark color of the pulp. This pulp could not be used immediately as
to produce a white grade paper product. Thus, a bleaching process must be carried
out to whiten the pulp.
Care must be observed so as to prevent the cellulose
degradation. Sodium hypochlorite will be used as bleaching chemical.
33
AgriWaste Paper Industry
Refining
The refiner is designed to fibrillate the cellulose fibers. Paper that has
been made from refined pulp has a greater resistance to tearing and bursting than
that from unrefined pulp.
In this process, the addition of various additives such as rosin, alum,
starch and talc are performed. The sizing of paper (prevention of ink penetration) is
accomplished by adding rosin and alum. The talc is also added to improve the
quality of paper in terms of opacity, brightness and finish of the sheet. Starch is
added to give firmness, stiffness, and strength particularly to the surface of the
sheet.
Paper Machine
This huge machine is fed the stock, which is about 99 % water, and
produces a finished roll paper. The most widely used machine is the Fourdrinier
machine after the two brothers who perfected it. The stock is pumped into the first
part of the machine, the head box. Here the stock is given a final mixing, and
turbulence is removed so that the flow into the rest of the machine is smooth and
even. The stock leaves the head box through the slice, an unjustable nozzle that
controls the flow of stock onto a wire mesh.
The wire mesh, sometimes called the Fourdrinier wire, is the mold for
forming a continuous sheet of paper, or web. The wire is an endless belt that acts as
conveyor belt. As stock is put on one end, the wire moves along and shakes to
interlace, or felt the fibers. Water drains out through the opening of the mesh. As it
approaches or reaches the end of the wire, the web may pass under a roller which
compact the fibers. From the wire, the web of paper, which is about 80% water, is
carried to press section of the machine. From presser, paper is transferred to the
dryer, a series of metal rollers.
34
AgriWaste Paper Industry
Packaging
The last stage in papermaking is creating a sheet size by means of paper
cutters. The dried huge sheet of papers will be passed through the paper cutter for
the desired bond paper size of 8.5” x 11”.
35
AgriWaste Paper Industry
MATERIAL BALANCE MAJOR ASSUMPTIONS
Duster
Dust removed – 0.3% of pulp fed
Mixer1
NaOH – 12% solution
4 tons- of pulp
ton of NaOH solution
Digester
Corn Stover composition:
• lignin (35%)
• cellulose (65%)
Washer1
Water added – 70% of the pulp fed
Black Liquor composition
• All NaOH fed
• 35% of Corn Stover fed
• 67% of total Water fed
Screens
Water removed - 75% of total Water Input
Bleacher
1 ton NaOCl solution
100 tons pulp
NaOCl solution Bleaching Agent (15% NaOCl, 85% Inert)
Washer2
Water Added – 70% of pulp fed
Water removed = 5% pulp, all NaOCl solution, 70% total H2O (wastes)
36
AgriWaste Paper Industry
Refiner
Alum – 10% of pulp fed
Rosin – 10% of pulp fed
Mixer2
8 tons of pulp
Talc =
1 tons talc
Starch – 12% of pulp fed
Fourdrinnier Machine
Water evaporated from the wet pulp – 94.5 % water fed
Packaging
Waste Paper – 2% paper fed
37
AgriWaste Paper Industry
OVERALL MATERIAL BALANCE
Figure 5. Overall Material Balance
38
AgriWaste Paper Industry
DETAILED MATERIAL BALANCE
Basis: 39.76 MT/day
39
AgriWaste Paper Industry
40
AgriWaste Paper Industry
SCREEN
INPUT = 52.32 MT
MT
%
Wet Pulp
52.32
100
OUTPUT = 32.52 MT
MT
%
Pulp
32.52
100
OUTPUT = 19.80
MT
%
Waste Water 19.80 100
41
AgriWaste Paper Industry
42
AgriWaste Paper Industry
43
AgriWaste Paper Industry
ENERGY BALANCE
Q = mCp∆T = m(Hv – Hl)
Digester
mcorn stover Cpcorn stover ∆T + mwater CpH20 ∆T + mNaOH CpNaOH ∆T
msteam =
(Hv – Hl)
msteam =
{(39.88 MT)(1.33978)kJ/mole-K(170-25)K + (8.77 MT)(4.16868) kJ/moleK (170-25)K + (1.20MT)(.00451402) kJ/mole-K (170-25)K}
(2793.3-104.89)kJ/mole
msteam =
4.87 MT
Fourdrinnier Machine
mcorn stover Cpcorn stover ∆T + mwater CpH20 ∆T
msteam =
(Hv – Hl)
{(24.63MT)(1.33978) kJ/mole-K (170-25)K+(55.01MT)(4.1868 kJ/moleK)(170-25)K+2260.872)}
(2793.3-104.89)kJ/mole
msteam =
msteam =
60.47 MT
Boiler (Diesel)
mcorn stover Cpcorn stover ∆T + mwater CpH∆T
mDiesel =
mDiesel =
mDiesel =
(Hv – Hl)/heating valueDiesel
{(24.63MT)(1.33978) kJ/mole-K (170-25)K+(55.01MT)(4.1868 kJ/moleK)(170-25)K+2260.872)}
(2793.3-104.89)kJ/mole/(46000)
2.65 MT
44
AgriWaste Paper Industry
PROCESS FLOWCHART
45
AgriWaste Paper Industry
EQUIPMENT SPECIFICATIONS
Hours per day
Percent full
24.000
0.650
Shredder
feed (MT)
density(MT/m3)
feed (MT/hour)
feed volume (m3)
corn stovers
input
40.000
1.560
1.667
1.068
total
40.000
1.068
volume of equipment
1.644
Quantity
Capacity
Height
Length
Width
Power Requirement
Dimensions
pc/s
m3
m
m
m
kW
1.000
1.644
1.677
1.400
0.700
1.119
Material of Construction:
•
•
•
Low alloy cast Grid Lock, Lower Grid Bars & Lower Breaker Bar
Low alloy cast Top Discharge Grid (incorporating variable
faceplate)
Stainless steel blade and body
Duster
feed (MT)
density(MT/m3)
feed (MT/hour)
feed volume (m3)
corn stovers
input
40.000
1.560
1.667
1.068
total
40.000
1.068
volume of equipment
1.644
Dimensions
Quantity
1.000
pc/s
Capacity
1.644
m3
Height
1.667
m
Length
1.400
m
Width
0.700
m
Power Requirement
1.119
kW
Material of Construction:
•
Stainless steel construction in compact design with trough type
trays
46
AgriWaste Paper Industry
input
NaOH
water
total
volume of equipment
feed (MT)
1.196
8.774
9.970
Mixer1
density(MT/m3)
1.040
1.000
Quantity
Capacity
Height
Diameter
Power requirement
1.000
0.636
1.480
0.740
0.559
feed (MT/hour)
0.050
0.366
feed volume (m3)
0.048
0.366
0.413
0.636
Dimensions
pc/s
m3
M
M
kW
Material of Construction:
designed as a compact, water pressure-tight unit including
propeller and integrally cast installation bracket for the
attachment on the square guide tube
•
Motor housing and propeller made
stainless steel
•
Digester
input
feed (MT)
density(MT/m3)
feed (MT/hour)
feed volume (m3)
corn stovers
39.880
1.560
1.662
1.065
caustic soda
1.196
1.040
0.050
0.048
water
8.774
1.000
0.366
0.366
total
49.850
1.479
volume of equipment
2.275
Dimensions
Quantity
3.000
pc/s
Capacity
2.275
m3
Height
2.263
m
Diameter
1.131
m
Material of Construction:
•
Incoloy alloy 800 is used, must have high strength and resist
oxidation, carburization, and other harmful effects of hightemperature exposure.
47
AgriWaste Paper Industry
Boiler
feed (MT)
density(MT/m3)
feed (MT/hour)
feed volume (m3)
water
input
65.333
1.000
2.722
2.722
total
65.333
2.722
volume of equipment
4.188
Dimensions
Quantity
1.000
pc/s
Capacity
4.188
m3
Height
2.773
m
Diameter
1.414
m
Material of Construction:
•
Novel steel construction solid-fuel firing boiler for civil
heating applications comprises a space portion defined by
side, bottom, cover, front and rear walls forming therein
an interspace for water to be heated
Blow Tank
input
pulp
feed (MT)
49.850
total
49.850
density(MT/m3)
0.720
feed (MT/hour)
2.077
2.885
volume of equipment
4.438
Dimensions
Quantity
1.000
pc/s
Capacity
4.438
m3
Height
2.287
m
Diameter
1.352
m
Material of Construction:
•
feed volume (m3)
2.885
Solid stainless steel
48
AgriWaste Paper Industry
Washers 1
pulp
input
feed (MT)
49.850
density(MT/m3)
0.720
feed (MT/hour)
2.077
feed volume (m3)
2.885
water
71.214
1.000
2.967
2.967
total
121.064
5.852
volume of equipment
9.003
Dimensions
Quantity
1.000
pc/s
Capacity
9.003
m3
Height
1.470
m
Length
3.500
m
Width
1.750
m
Power Requirement
2.24
kW
Material of Construction:
•
Stainless Steel with plastic segments
Screens
feed (MT)
density(MT/m3)
feed (MT/hour)
feed volume (m3)
pulp
input
25.922
0.720
1.080
1.500
water
26.696
1.000
1.100
1.100
total
52.318
2.600
volume of equipment
4.000
Dimensions
Quantity
1.000
pc/s
Capacity
4.000
m3
Height
1.280
m
Length
2.500
m
Width
1.250
m
Power Requirement
0.746
kW
Material of Construction:
•
Stainless steel construction and four blade hydrofoil spider
49
AgriWaste Paper Industry
input
pulp
sodium hypochlorite sol'n
total
volume of equipment
feed (MT)
32.521
1.987
34.508
Bleacher
density(MT/m3)
0.720
1.097
feed (MT/hour)
1.355
1.097
feed volume (m3)
1.882
0.075
1.957
3.012
Dimensions
Quantity
1.000
pc/s
Capacity
3.012
m3
Height
2.485
m
Diameter
1.242
m
Power Requirement
1.119
kW
Material of Construction:
•
Stainless steel
input
pulp
sodium hypochlorite soln
water
total
volume of equipment
feed (MT)
34.508
49.298
0.000
83.806
Washer 2
density(MT/m3)
0.720
1.097
1.000
Dimensions
Quantity
1.000
pc/s
Capacity
5.953
m3
Height
1.416
m
Length
2.900
m
Width
1.450
m
Power Requirement
1.119
kW
Material of Construction:
•
Stainless Steel with plastic segments
50
feed (MT/hour)
1.428
2.054
0.000
feed volume (m3)
1.997
1.872
0.000
3.869
5.953
AgriWaste Paper Industry
input
pulp
alum
rosin
talc
starch
water
total
volume of equipment
feed (MT)
41.395
2.463
2.463
4.226
2.955
38.244
91.745
Refiner
density(MT/m3)
0.561
0.881
1.073
1.746
0.561
1.000
feed (MT/hour)
1.725
0.103
0.103
0.176
0.123
1594
feed volume (m3)
3.174
0.116
0.096
0.101
0.219
1.594
5.200
8.001
Dimensions
Quantity
1.000
pc/s
Capacity
8.001
m3
Height
3.441
m
Diameter
1.721
m
Power Requirement
0.746
kW
Material of Construction:
•
Welded stainless steel
input
starch
talc
water
total
volume of equipment
Quantity
Capacity
Height
Diameter
Power Requirement
feed (MT)
4.226
2.463
5.914
12.603
Mixer2
density(MT/m3)
0.561
1.746
1.000
1.000
0.952
1.693
0.846
0.559
Dimensions
pc/s
m3
m
m
kW
Materials of Construction:
designed as a compact, water pressure-tight unit including
propeller and integrally cast installation bracket for the
attachment on the square guide tube
•
Motor housing and propeller made
stainless steel
•
51
feed (MT/hour)
0.176
0.103
0.246
feed volume (m3)
0.314
0.059
0.246
0.619
0. 0.952397403
AgriWaste Paper Industry
input
Treated pulp
total
volume of equipment
feed (MT)
91.745
91.745
Fourdrinier Machine
density(MT/m3)
0.720
feed (MT/hour)
3.823
feed volume (m3)
5.309
5.309
8.168
feed (MT/hour)
0.103
feed volume (m3)
0.085
0.085
0.131
Dimensions
Quantity
1.000
pc/s
Capacity
8.168
m3
Height
0.454
m
Length
6.000
m
Width
3.000
m
Power Requirement
2.237
kW
Material of Construction:
•
Open stainless steel head box; cantilevered stainless
fourdrinier with top granite rolls and rubber lined bottom
rolls, forming box, plain foils suction foils and suction boxes,
cantilevered suction couch, wire return rolls, wire stretch,
wire guides.
input
paper
total
volume of equipment
feed (MT)
2.463
2.463
Packaging
density(MT/m3)
1.201
Dimensions
Quantity
1.000
pc/s
Capacity
0.131
m3
Height
0.046
m
Length
2.400
m
Width
1.200
m
Power Requirement
0.75
kW
Materials of Construction:
•
Stainless steel body and sharp stainless steel blade
52
AgriWaste Paper Industry
Water Tank
input
feed (MT)
density(MT/m3)
feed (MT/day)
water
232.863
1.000
232.863
total
232.683
feed volume (m3)
232.863
232.863
volume of equipment
358.250
Water Tank
Quantity
5.000
pc/s
Capacity
71.650
m3
Height
7.146
m
Diameter
3.762
m
Material of Construction:
•
Tanks made of corrugated low carbon galvanized steel, lined with
hot bonded food-grade polymer
NaOCl Tank
input
NaOCl solution
total
feed (MT)
1.987
density(MT/m3)
1.097
feed (MT/2wks)
59.621
1.987
feed volume (m3)
54.349
54.349
volume of equipment
83.613
NaOCl Tank
Quantity
1.000
pc/s
Capacity
83.613
m3
Height
7.523
m
Diameter
3.762
m
Material of Construction:
• High density liner polyethylene tanks, modeled tank use for
aggressive corrosive chemicals
53
AgriWaste Paper Industry
Figure 11. Equipment Layout
54
AgriWaste Paper Industry
PLANT DESCRIPTION
Location
Choosing for the best plant site is very difficult. There are several influences that
we have to consider in selecting the most suitable site. Among which are the availability
of raw materials; climate; utilities such as transportation, communication, water
resource; wastewater disposal and dry waste disposal; and most especially the human
labor cost.
We have decided to construct our plant in Santiago City, Isabela. The availability
of the raw material is our main reason of selecting the site, since Isabela have much
production of corn based on the data gathered in the Bureau of Agricultural Statistics
(see Appendix C). Moreover, another source of raw material is the nearby province
Cagayan, which only takes 3 hours getting there. From the data that we have gathered
from Bureau of Agricultural Statistics, the Cagayan Valley Region (Region 2) is one of
the largest corn producers in the country.
Also, the accessibility of transportation facilities, the roads and the highways are
in good quality so it offers some advantages for the delivery of raw materials and
finished goods. Furthermore, the cost is minimal for labor and there is an adequate
supply of human resources. Provincial taxes are also low.
Figure 8. Plant Location Map
55
AgriWaste Paper Industry
Plant Size
The total land area of our plant is 6,496.36 m2. The plant has the perimeter of
322.40 m with the length and width of 80.6 m. The total building area is 4,942 m2 and a
free space of 1,554.20 m2. The plant follows the building and space ratio of 70% and
30% respectively. AgriWaste Paper Industry will consist of the following:
Administration Building (2 floors) – 278 m2
General Manager Office w/ Executive Secretary Room & Rest Room
HR, Purchasing and Cashier Department
Marketing and Finance Department
Canteen
Clinic
Reception Area or Lobby
Company Files Room
Conference Room
Seminar Room (for future expansion)
Comfort Rooms
Process Plant – 956.02 m2
Boiler House
Repair and Maintenance Room
Production Office w/ CR (Plant Head & Process Engineers)
Laboratory w/ CR (Quality Control Head & Lab Analysts)
Comfort Room
Warehouse (Raw Materials) – 2,995.14 m2
Office
Fillers Storage
Warehouse (Finished Goods) – 237 m2
Office w/ Comfort Room
Power House – 64 m2
Guard House w/ CR – 12 m2
Waste Water Treatment Plant – 400 m2
56
AgriWaste Paper Industry
Figure 12. Plant Layout
57
AgriWaste Paper Industry
Figure 12a. Plant Layout
58
AgriWaste Paper Industry
Figure 12b. Plant Layout
59
AgriWaste Paper Industry
ORGANIZATIONAL AND FINANCIAL STUDY
ORGANIZATIONAL CHART
In a business operation, the whole of the industry consists of various subsystems
and activities.
The company has been proposed that a chosen organizational
structure will be designed to accomplish effectively the objective of the company.
The company will adopt the basic form of organization which is through
departmentalization. The group work took into account the various tasks of the
subsystems so that there will be no overloading or under loading of works so as to
optimize each person’s capacity to do the works.
AgriWaste Paper Industry consists of 86 employees, working on eight hours per
day basis. For the personnel in the production like production workers, process
engineers, repair and maintenance, warehouse assistance, forklift operators and the
security personnel and nurses, shifting schedules will be implemented to
accommodate the continuous production of bond paper.
Figure 9. Organizational Chart
60
AgriWaste Paper Industry
JOB DESCRIPTION
General Manager
Functions
The general manager of the company shall initiate the organization’s objectives
and policies as well as formulate plans and programs. He/She is responsible for the
overall direction and control of the company’s entire operation. Also, he/she is liable for
the Quality Management System and achievement of its objectives as signified in the
quality policy. The General Manager also analyzes the act, decision and relation
needed. He/She is directly responsible to the board or the successful achievement of
organization’s objectives. It thus becomes the central task of the manager to reconcile
differences in approach, timing, effort, interest and to harmonize individual goals to
contribute to organizational goal.
Qualifications
Male/Female, between 40 to 50 years of age. At least 10 years of excellent
experience in managerial work.
Executive Secretary
Functions
The secretary takes down notes and dictations and supplies the manager or
his/her superior with up-to-date appointments. He/she keeps the minutes of the
meetings and submits the same thereafter. He/she records the works of the manager
and transmits the policies of the department where he/she belongs.
Qualifications
Male/Female, 21 to 30 years of age. Graduate of 4 years course with excellent
typing skills and has the knowledge in computer software. With at least 3 years of
experience.
HR Manager
Functions
The HR Manager is responsible for the overall directions and control of human
resources services and activities and for the effective implementation of the company’s
programs.
Qualifications
Male/Female, 30 to 35 years of age. Graduate of Management Course with at
least 5 years of excellent experience of handling employees.
HRD Staff
Functions
The company will hire two HRD staffs. They will facilitate hiring, time keeping
and will be in charge of the benefits and records of the employees.
Qualifications
Male/Female, 25 to 30 years of age. College graduate from a respective
university.
61
AgriWaste Paper Industry
Nurse
Functions
He/she is in charge of looking after and caring for the health of the employees of
the company. This person also keeps back of the health records and the health history
of the employees.
Qualifications
Male/Female, 23 to 35 years of age. Must be a graduate of medical course and
with license.
Financial Manager
Functions
The financial manager is responsible for the management of all financial activities
of the corporation, coordinates in the financing act, manage financing operations, and
ensure proper fund management through practical use of all available investment and
financing tools. He/she actively participates in the company’s profitability at all times.
Qualifications
Male/Female, 21 to 25 years of age. Accounting graduate or any related course
from a reputable school. Have four years experience. Board passer is advantage but
not as requirement.
Chief Accountant
Functions
The chief accountant reports to the financial manager the financial situation of
the company. It also oversees the proper allocations of funds.
Qualifications
Male/Female, 21 to 28 years of age. Graduate of BS Accountancy. Must be a
board passer and have two years experience. Computer Software knowledge is a
must.
Purchasing Supervisor
Functions
The purchasing supervisor is responsible of supervising the purchase of needed
equipment, raw materials and materials procurement fines.
Qualifications
Male/Female, between 25 to 30 years of age. Must be graduate of Industrial
Engineering with at least 3 years of experience and computer literate.
Accounting Staff
Functions
The accounting staffs help in keeping maintaining records of accounting records
of the company, financial statements, analysis of accounts and also responsible for the
technical reports on the financial to be kept as record of the company.
Qualifications
Male/Female, 21 to 28 years of age. Graduate of 4 year course with knowledge
in basic accounting and computer software application.
62
AgriWaste Paper Industry
Purchasing and Payroll Staff
Functions
Purchasing and payroll staffs are responsible in purchasing tools needed in the
company such as office supplies. They are also responsible for allocating the salaries of
the company employees.
Qualifications
Male/Female, 21 to 28 years of age. Graduate of any accounting course. Must
have computer software knowledge.
Production Manager
Functions
He is the one responsible for the sufficient and quality supply of finished product.
He supervises plant operations intensely quality control and sees to it that a safe
working environment is maintained in the plant site.
Qualifications
Male, 25 to 35 years of age. Must be a chemical engineering graduate and have
at least 5 years experience in handling plant operation.
QC Head
Functions
The quality control head is responsible in supervising the production of high
quality product and reports to the production manager for any problem or improvement
of the product to be produced.
Qualifications
Male/female, 23 to 30 years of age. Must be a chemical engineering graduate
and have two years of experience.
Laboratory Analyst
Functions
There will be three lab analysts for the production and one for the raw materials.
They are responsible for testing the raw materials and finished goods to know whether
they met the set quality standards. They also perform other duties asked by the quality
control head.
Qualifications
Male/Female, at least 21 years of age. Graduate of BS Chemistry or Chemical
Engineering. Must have the knowledge in computer software and board passer.
Experience is an advantage.
Plant Head
Functions
The plant head is responsible in overseeing the plant operations including
maintenance of safe working environment in the plant site. Also responsible for the
sufficient and quality production.
Qualifications
Male, 25 to 30 years of age. A graduate of BS Chemical Engineering course and
board passer. Must have at least 3 years of experience.
63
AgriWaste Paper Industry
Process Engineer
Functions
The process engineers are the one responsible in the monitoring of the quality
and quantity being produced in the operation. They are also responsible in directing the
mechanics in any trouble done during the operation.
Qualifications
Male/Female, 22 to 28 years of age. Must be a Chemical Engineering graduate
or an Industrial Engineering graduate with experience in monitoring of industrial
process. Board passer is a must.
Production Laborers
Functions
They are the people in charge of the operation involve in the production process.
They are under the supervision of the process engineers and so required to report to
the plant head.
Qualifications
Male/Female. 25 to 35 years of age. Must have at least four years of experience
in working in any industry.
Janitors
Functions
Janitors are responsible for the cleanliness of the plant, all the buildings, and the
open areas of the company’s premises. They ensure the work environment is clean
enough for work and they may also take part in running errands when needed.
Qualifications
Male/Female, 20 to 30 years of age. Hardworking, responsible and punctual.
Security Personnel
Functions
They are the people responsible for protecting and keeping the company
premises safe and secure, for assuring peace and order within the walls of the
company.
Qualifications
Male in good health, strong, ready to work and hard working.
Mechanics
Functions
The mechanics is the aid of mechanical engineer. The company will hire three
mechanics. They will personally repair whatever equipment in trouble including the
trucks and utility vehicle.
Qualifications
Male, at least 21 years of age. Graduate of any related courses with knowledge
in industrial equipment. Experience is not necessary but an advantage.
64
AgriWaste Paper Industry
Electricians
Functions
There will be three electricians hired by the company. They facilitates the
electrical maintenance and repair of the plant including the administration building.
Qualifications
Male, at least 21 years of age. Graduate of any two-year electrical course.
Experience is an advantage.
Warehouse Head
Functions
He is responsible for looking after and managing the warehouses. He controls
the finished goods and raw materials that go in and out of the warehouse.
Qualifications
Male, 30 to 35 years of age. Must have at least 4 years experience with good
moral character.
Warehouse Assistant
Functions
Responsible in assisting the warehouse head. He acts as the security guard of
the warehouse.
Qualifications
Male, 25 to 30 years of age. Must have experience, in good health, strong, ready
to work and hard working.
Drivers
Functions
They are the people in charge in the transporting raw materials to and from the
company and also in charge of transporting the product to the consumers.
Qualifications
Male/Female, 23 to 35 years of age. Has at least one year experience in driving
trucks and must hold a professional driver’s license.
Forklift Operators
Functions
Forklift operators are the drivers responsible in transporting raw materials to be
loaded in the equipment and finished goods to be stored in the warehouse.
Qualifications
Male, 25 to 30 years of age. Have a good driving skills and must know how to
operate the forklift equipment. Driver’s license is a must.
Marketing Manager
Functions
The marketing manager is responsible for the overall directions and coordination
of sales and customer services and for ensuring that the customer requirements are
met through the review of contracts. He/she develops marketing plans, strategies, as
well as the promotion of company’s product.
65
AgriWaste Paper Industry
Qualifications
Male/Female, 30 to 35 years of age at least 5 years of excellent experience.
Must be computer literate.
Marketing Staff
Functions
The marketing staffs are the one responsible in keeping the record of sales and
production of the company. They are also responsible in doing technical reports
needed for the prospect customers and assist also the customers.
Qualifications
Male/Female, 21 to 28 years of age. A graduate of any Marketing course. Have
a basic knowledge in communication skills and computer software.
Sales Representatives
Functions
The sales representatives are composed of two persons. They are the one
assisting and persuading prospective customers to buy a commodity in a face to face
situation. Thus, they must equip themselves of sales knowledge for an efficient
performance.
Qualifications
Male/Female, 21 to 25 years of age. Graduate of four years course with
excellent communication skills and pleasing personality.
66
AgriWaste Paper Industry
POLICIES, RULES AND PROCEDURES
Personal
The advancement of the employee with the organization depends on how he
makes the most of various opportunities offered by the company and how well he
performs his duties and responsibilities.
Hiring
In order to maintain its reputation of providing the highest quality of work with in a
target schedules, the company needs competent employees to maintain day-to-day
operations thus, achieving its business objectives. The employee’s success is the
company’s success.
For this reason, the company is careful in selecting its
employees by giving written examination and personal interviews. Also, conducts
follow up on references. Other factors are ability, experience, training, intelligence,
character, and health.
The applicants are required to pass for their medical
examination conducted by a physician.
Promotion
As a policy, the company offers all employees the chance to be in higher position
in office which more responsibilities but higher payment on the basis of
demonstrated ability, diligence and professional consistence.
Wage Policy
Management upholds the principles of equal work. Company wage rate compare
fairly with those other firms in the industry. Generally, the rate pay depends on the
position of the employee and his effectiveness of work.
Salary increase is
recommended by the supervisor based on the merits of promotion. Basically, the
company will render a 5% increase in salary annually.
Payment of Salaries
All employees will be paid on a monthly basis and will receive their salary every
th
15 and end of the month.
67
AgriWaste Paper Industry
GANTT CHART OF PRE-OPERATING ACTIVITIES
2006
ACTIVITIES
Oct
Nov
Dec
Jan
1. Approval of the study
2. Registration of the company
Security and Exchange Commission
Department of Trade and Industry
3. Plant Site Acquisition
4. Fencing and Land Dev't
5. Rental of Office Space
6. Application for an ECC (DENR)
7. Hire Manpower
8. Registration with the SSS, BIR,
PhilHealth etc.
9. Office Supplies Acquisition
10. Registration with the Intellectual
Property Office
11. Plant and Bldg Construction
12.Transfer to the Office Building
13. Ordering of Plant Equipment
14. Arrival of Plant Equipment
15. Installation of Plant Equipment
16. Purchase of Transport Vehicles
17. Training Personnel
18. Purchase of Raw Materials
19. Trial Run
20. Laboratory Testing
21. Marketing Strategy
22. Start of the Operation
Figure 10. Gantt Chart
68
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
Oct
AgriWaste Paper Industry
APPENDICES
Appendix A. Historical and Projected Demand Table
Historical Demand
Year
Population
(ages 4-69)
Consumption
(7 pcs
paper/personyear)
Demand
(pcs/ person/
year)
Demand
(MT / Year)
Population
of Region II
Population
of Isabela
1995
57,184,874.0
2555
146107353070
660,405.24
2,536,035.00
1,160,721
1996
58,952,993.0
2555
150624897115
680,824.53
2,614,447.55
1,196,610
1997
60,447,018.0
2555
154442130990
698,078.43
2,680,704.57
1,226,935
1998
61,941,046.0
2555
158259372530
715,332.36
2,746,961.73
1,257,260
1999
63,435,071.0
2555
162076606405
732,586.26
2,813,218.76
1,287,586
2000
64,933,190.0
2555
165904300450
749,887.44
2,879,657.35
1,317,994
2001
66,410,802.0
2555
169679599110
766,951.79
2,945,186.49
1,347,986
2002
67,888,417.0
2555
173454905435
784,016.17
3,010,715.76
1,377,978
2003
69,366,031.0
2555
177230209205
801,080.55
3,076,244.99
1,407,970
2004
70,847,695.0
2555
181015860725
818,191.69
3,141,953.84
1,438,045
2005
71,836,686.0
2555
183542732730
829,613.15
3,185,813.61
1,458,119
2006
73,702,095.5
2555
188308854119
851,156.02
3,268,540.80
1,495,982
2007
75,179,053.5
2555
192082481809
868,212.82
3,334,040.94
1,525,961
69
AgriWaste Paper Industry
Projected Demand
Population
(ages 4-69)
Consumption
(7 pcs
paper/personyear)
Demand
(pcs/ person/
year)
Demand
(MT / Year)
Population
of Region II
Population
of Isabela
2008
76,656,011.5
2555
195856109499
885,269.61
3,399,541.08
1,555,940
2009
78,132,969.5
2555
199629737189
902,326.41
3,465,041.22
1,585,919
2010
79,609,927.5
2555
203403364879
919,383.21
3,530,541.36
1,615,898
2011
81,086,885.5
2555
207176992569
936,440.01
3,596,041.49
1,645,877
2012
82,563,843.5
2555
210950620259
953,496.80
3,661,541.63
1,675,856
2013
84,040,801.5
2555
214724247949
970,553.60
3,727,041.77
1,705,834
2014
85,517,759.5
2555
218497875639
987,610.40
3,792,541.91
1,735,813
2015
86,994,717.5
2555
222271503329
1,004,667.20
3,858,042.05
1,765,792
2016
88,471,675.5
2555
226045131019
1,021,723.99
3,923,542.19
1,795,771
2017
89,948,633.5
2555
229818758709
1,038,780.79
3,989,042.33
1,825,750
Year
Appendix B. Sample Computations
Historical and Projected Demand of Paper
Year 1995
Population = 57,184,874
Consumption = 7 * 365 pcs paper/person-year
= 2555 pcs paper/person-year
Demand (MT of paper/Year)
= (Population*Consumption) / 500pcs*
2.26kg/ream*1MT/1000kg
= 146,107,353,070 / 500 * 2.26 * 1/1000
= 660,405.24 MT of paper/Year
Market Share
Year 2007
Population = 75,179,053.54
70
AgriWaste Paper Industry
Consumption = 7 pcs-paper * 365 = 2555 pcs-paper/person-year
Demand = Population * Consumption = 192,082,481,809 pcs/person/year
Demand (MT/Year) = 192,082,481,809 500pcs* 2.26kg/ream*1MT/1000kg
= 868,213
Production = 13,891.41 MT of paper /Year
Market Share = Production / Demand
= (13,891.41 / 868,213) *100
= 1.60 %
Price Inventory of Raw Materials
Corn Stovers (6 months)
Pre-operating period
Beginning Inventory (BIpre-op) = 0
Usage = Corn Stover input from Material Balance * 30days operation
= 40 MT * 30 = 1,200.00
Ending Inventory (EIpre-op) = (BI2007) = Usage2007 * 6months/12
= Corn Stover input from Material Balance * 360
= 40 * 360 * 6/12
= 7,200
Purchase = EI + Usage – BI
= 7,200 + 1,200 – 0
= 8,400.00
Price (Php/Ton) = 50 Php/Ton
Beginning Inventory (BI), Php = 0 * Price = 0
Usage (Php) = Price * Usage = 50 * 1,200 =60,000.00 Php
Ending Inventory (EI), Php = BI2007 = Usage2007,php / 2 = (Price *
Usage2007)/2
= (50 * 14,400)/2
= 360,000.00
Purchase = Usage + EI – BI
= 60,000.00 + 360,000.00 – 0
= 420,000.00
71
AgriWaste Paper Industry
Year 2007
Beginning Inventory (BI2007) = EIpre-op = 7,200
Usage = Corn Stover input from Material Balance * 360 days
= 14,400
Ending Inventory (EI2007) = (BI2008) = Usage2008 * 6months/12
= Corn Stover input from Material Balance * 360
= 40 * 360 * 6/12
= 7,200
Purchase = EI + Usage – BI
= 7,200 + 14,400 – 7,200
= 14,400
Price (Php/Ton) = 50 Php/Ton
Beginning Inventory (BI), Php = EIphp, Php = 360,000.00
Usage (Php) = Price * Usage2007= 50 * 14,400 = 720,000.00 Php
Ending Inventory (EI), Php = BI2008 = 360,000.00
Purchase = EI + Usage – BI
= 360,000.00 + 720,000.00 – 360,000.00
= 720,000.00
NaOH (1 month)
Pre-operating period
Beginning Inventory (BIpre-op) = 0
Usage = Caustic soda input from Material Balance * 30days operation
= 1.20 MT * 30 = 35.89
Ending Inventory (EIpre-op) = (BI2007) = Usage2007 * 1month/12
= Caustic soda input from Material Balance *
360
= 1.20 * 360 * 1/12
= 35.89
Purchase = EI + Usage – BI
= 35.89 + 35.89 – 0
= 71.78
Price (Php/Ton) = 15,000 Php/Ton
Beginning Inventory (BI), Php = 0 * Price = 0
Usage (Php) = Price * Usage = 15,000 * 35.89 = 538,380.00 Php
Ending Inventory (EI), Php = BI2007 = Usage2007,php / 12 = (Price *
Usage2007)/12
= (15000 * 430.70)/12
= 538,380.00
72
AgriWaste Paper Industry
Purchase = EI + Usage – BI
= 538,380.00 + 538,380.00 – 0
= 1,076,760.00
Year 2007
Beginning Inventory (BI2007) = EIpre-op = 35.89
Usage = Caustic soda input from Material Balance * 360 days
= 430.70
Ending Inventory(EI2007) = (BI2008) = Usage2008 * 1month/12
= (Caustic soda input from Material Balance *
360)1/12
= (1.20 * 360)1/12
= 35.89
Purchase = EI + Usage – BI
= 35.89 + 430.70 – 35.89
= 430.70
Price (Php/Ton) = 15,000 Php/Ton
Beginning Inventory (BI), Php = EIpre-op, Php = 538,380.00
Usage (Php) = Price * Usage = 15,000 * 430.70 = 6,460,560.00 Php
Ending Inventory (EI), Php = BI2008 = Usage2008,php /12 = (Price *
Usage2008)/12
= 549,147.60
Purchase = EI + Usage – BI
= 549,147.60 + 6,460,560.00 – 538,380.00
= 6,471,327.60
Variable Transport
Shredder
Year 2007
Mass (kg) = corn stover input = 40 MT * 1000 = 40,000kg
Gravity = 9.81 m/s2
Force = m * g = 40,000 * 9.81 = 392400 kg-m/s2
Distance = 4 m
Work = Force * Distance = 392400 * 4 = 1569600 kg-m2/s2
Power = Work / Time = (1569600 / 300)Watt *(1/1000)kW = 5.23 kW
73
AgriWaste Paper Industry
Consumption (kWh/day) = Power * Hours/day
= 5.23kW * [(300sec/3600) hour * 24] day
= 10.46
Consumption (kWh/Yr) = Consumption (kWh/day) * 360
= 941.76
Equipment Specifications
Percent full – 65%
Shredder
Input
Corn Stovers = 40 MT/day = 40 / 24hours = 1.667 MT/hour
Density of corn stover = 1.560 MT/m3
Total volume of Input = Input / Density = 1.667 / 1.560
= 1.068 m3
Total Volume of Shredder = 1.068 / 0.65 = 1.644 m3
Duster
Input
Corn Stovers = 40 MT/day = 40 / 24hours = 1.667 MT/hour
Density of corn stover = 1.560 MT/m3
Total volume of Input = Input / Density = 1.667 / 1.560
= 1.068 m3
Total Volume of Duster = 1.068 / 0.65 = 1.644 m3
Mixer 1
Input
Sodium Hydroxide (NaOH) = 1.196 MT/day = 1.196 / 24hours = 0.050 MT/hour
Water (H2O) = 8.774 MT /day = 8.774 / 24hours = 0.366 MT/hour
74
AgriWaste Paper Industry
Density of NaOH = 1.560 MT/m3
Density of H2O = 1.00 MT/m3
Total Feed Volume = Input Feed / Density = (0.050/1.560) + (0.366/1.00)
= 0.413 m3
Total Volume of Mixer = 0.413 / 0.65 = 0.636 m3
Equipment Optimization
Shredder
Year 2007
Total feed input (MT/hr) = 1.6667
Maximum Feed Capacity Shredder = 1.6667/0.65 full= 2.5641
Percentage = (2.5641/2.2436) * 100 = 65%
Duster
Year 2007
Total feed input (MT/hr) = 1.6667
Maximum Feed Capacity Shredder = 1.6667/0.65 full= 2.5641
Percentage = (2.5641/2.2436) * 100 = 65%
Price Inventory of Finished Goods
Price of bond paper will increase by 1% every five years
Pre-operating period
Beginning Inventory (BIpre-op) = 0
Production = 38.06 MT/day * 30days operation
= 1,141.76 MT
Ending Inventory (EIpre-op) = (BI2007) = Production2007 * 1/12
= (38.06 MT/day * 360 days operation) /12
= 1,141.76
75
AgriWaste Paper Industry
Sales (MT) = Production + Ending Inventory – Beginning Inventory
= 1,141.76 + 1,141.76 – 0
= 2283.52
Price / kg(Php/kg) = 37.62
Sales (Php) = Price * Sales = 37.62 Php/kg * (2062.44 *1000)
= 85,905,971Php
Year 2007
Beginning Inventory (BI2007) = EIpre-op = 1,141.76
Production = 38.06 MT/day * 360days operation
= 13701.11 MT
Ending Inventory (EI2007) = (BI2007) = Production2007 * 1/12
= (38.06 MT/day * 360 days operation) /12\
= 1141.76
Sales (MT) = Production + Ending Inventory – Beginning Inventory
= 13701.11 + 1141.76 – 1,141.76
= 13701.11
Price / kg(Php/kg) = 37.62
Sales (Php) = Price * Sales = 37.62 Php/kg * (2062.44 *1000)
= 515,435,828 Php
Water Projection.
Pre-operating period
Variable (MT) = total water used in the process * 30days operation = 6,985.88
MT
Fixed (MT) = total number of personnel * water consumption
= 86 * 0.2
= 516 MT
Total water consumption (MT) = Variable + Fixed
= 5,732.24 + 516
= 7,501.88 MT
= 7,501.88 m3
76
AgriWaste Paper Industry
Total Water Cost (Php) = 7,501.88 m3 * 12 Php/m3
= 90,022.53 Php
Electricity Consumption
Air conditioner unit
Number of Unit = 6
Power Requirement = 1.00 kW
Hours/day = 8.00 hrs/day
Total Power Requirement = Power Requirement * Number of Unit
= 1.00 kW * 6
= 6 kW
Consumption (kWh) = Total Power Requirement * Hours/day
=6*8
= 48 kWh
Cost/kWh = 8.40 Php/kWh
Cost/Day = Cost/kWh * Consumption (kWh)
= 8.40 * 48
= 403.2 Cost/day
Electricity Projection
Year 2007
Fixed (kWh/Year) = 362,272
Variable (kWh/Year) = 4998125
Total (kWh/Year) = 4998125 + 362,272 = 5360398
Cost/kWh = 8.50
Total Cost / Year = 5360398 * 8.50
= Php 45,563,381
Fuel Projection
Diesel Fuel
Year 2007
Consumption/Yr (MT) = 952.78
Cost/L = 29 Php/L
Cost/Year = Consumption * Cost/kg * 1000
= 22,781,513 Php
77
AgriWaste Paper Industry
Raw Material Transportation
Year 2007
Kilometer = 400 Km
Fuel Consumption = 0.36 Liter/Km
Cost/Liter = 29.00 Php/L
Cost/Year = Kilometer * Fuel Consumption * Cost/Liter * 2
= 8352 Php/Year
Finished Goods Transportation
Year 2007
Kilometer = 300 Km
Fuel Consumption = 0.36 Liter/Km
Cost/Liter = 29.00 Php/L
Cost/Year = Kilometer * Fuel Consumption * Cost/Liter * 2
= 37584 Php/Year
Pre-operating Salaries and Fringe Benefits
Assumption: 25% Fringe Benefits
General Manager
There will be only one general manager.
Salary = Php 100,000.00
Months = 11
Total Salary = 100,000 (11) = Php 1,100,000
Fringe Benefits = 0.25 (Php 1,100,000)
= 275,000
Total Compensation = Total Salary + Fringe Benefits
= 1,100,000 + 275,000
= 1,375,000
Executive Secretary
There will be only one executive secretary.
Salary = Php 13,000.00
Months = 11
78
AgriWaste Paper Industry
Total Salary = 13,000 (11) = Php 143,000
Fringe Benefits = 0.25 (Php 143,000)
= 37,750
Total Compensation = Total Salary + Fringe Benefits
= 143,000 + 37,750
= 178,750
Land and Building Cost
Building Cost
Administration (2 floors)
Area = 278 m2
Cost / Area = Php 15,000.00
Cost (Php) = Area * Cost/Area + (10,000 * Area)
= 278 * 15,000 + (10,000 * 278 )
= 6,950,000 Php
Depreciation = Total Cost / Useful Life
= 6,950,000 / 40
= 173,750
Land Cost
Length = 80.60 m
Width = 80.60 m
Total Land Area = Length * Width
= 80.60 m * 80.60 m
= 6,589.55 m2
Perimeter = (Length * 2) + (Width * 2)
= (80.60 * 2) + (80.60 * 2)
= 322.40 m
Building Space = 4,942 m2
Free Space = Total Land Area – Building Space
= 6,589.55 m2 - 4,942 m2
= 1,647.39
Cost/Area (Php/m2) = 750.00
Total Land Cost = Total Land Area * Cost/Area
= 6,589.55 m2 * 750.00
= Php 4,942,165
79
AgriWaste Paper Industry
Land Improvement Cost
Gate
Perimeter = 10 m
Cost/Perimeter = Php10,000
Cost (Php) = Perimeter * Cost/Perimeter
= 10 * 10,000
Fence
Perimeter = total perimeter of land – 10 m of gate
= 258.20 – 10
= 248.20 m
Cost/Perimeter = 2,500 Php/m
Cost (Php) = Perimeter * Cost/Perimeter
= 248.20 * 2,500
= 620,500
Equipment Cost
Shredder
FOB, USD = 1,360
FOB, PHP = 1,360 * 55 = 74,800
C&F = FOB (Php) * 1.05
= 754,800 * 1.05
= 78,540
CIF = C&F * 1.01
= 78,540 * 1.01
= 79,325
Service = CIF * 1.005
= 79,325 * 1.005
= 79,722
Import Duty = Service * 1.12
= 79,722 * 1.12
= 89,289
Delivery Cost = Rate is based from AJRJ Trucking = 24,116 Php
80
AgriWaste Paper Industry
Factors account for Solid processing Equipment from Perry’s Handbook
Solids Processing
0.19
0.07
0.13
0.03
0.33
0.03
0.1
0.3
Total = 1.18
Total Price = ((C&F + CIF + Service + Import Duty) Factor) + Delivery Cost
= ((78,540 + 79,325 + 79,722 + 89,289) 1.18) + 24,116
= 409,830 Php
Useful Life = 40
Depreciation = Total Price / Useful Life
= 409,830 / 40
= 10,246
Taxes and Licenses
Land and Building Cost
Total Cost (Php) = Php 39,852,841
Tax/License (1.5%) = 39,852,841 * 0.015
= 597,792.62
Insurance (Building) (1.5%) = 35,179,500 * 0.015
= 527,693
Breakeven
Break-even Volume = V
Revenue = Cost or Profit = 0
Selling Price * Break-even volume
= Revenue Cost of Sales (such as Raw Materials, Electricity,
Water etc.) + Administration and Marketing Expenses (Sales Tax,
Delivery, etc.,)
81
AgriWaste Paper Industry
Break-even Selling Price = P
Sales Volume *Break-even Selling Price =
= Revenue Cost of Sales (such as Raw Materials, Electricity,
Water etc.) + Administration and Marketing Expenses (Sales Tax,
Delivery, etc.,)
Year 2007
Break-even Volume = (307,543,700 + 43,662,708 )/37.62
= 9,335,630
Break-even Selling Price = (307,543,700 + 43,662,708 )/ 9,335,630
= 153,801
Payback Period
∑Profit = Equity
Year
Profit
Todate Profit
1
P1
P1
2
P2
P1 + P2
.
.
.
.
.
.
n-1
Pn-1
P1 + P2 + .... Pn-1
n
Pn
P1 + P2 + .... Pn-1 + Pn
Payback Period = {(n+1) + Equity – [P1 + P2 + ......... Pn-1]}/ Pn
PAYBACK PERIOD
Equity
Year
2007
2008
2009
2010
2011
191,000,000
Profit
108,735,660
89,986,776
86,713,173
83,637,483
78,477,282
To date Profit
108,735,660
198,722,437
285,435,610
369,073,093
447,550,374
Payback Period = 1 + (195,000,000 – 108,735,660)/ 89,986,776
= 1.91 year
82
AgriWaste Paper Industry
Rate of Return
i = Rate of Investment in %
Equity = PY1/(1+i)1+ PY2/(1+i)2+ PY3/(1+i)3+ ........ PY10/(1+i)10 + PY11/(1+i)11
By Trial and Error:
i % = 47.93%
83
AgriWaste Paper Industry
Appendix C. Isabela Corn Production
84
AgriWaste Paper Industry
85
AgriWaste Paper Industry
86
AgriWaste Paper Industry
87
AgriWaste Paper Industry
88
AgriWaste Paper Industry
89
AgriWaste Paper Industry
90
AgriWaste Paper Industry
91
AgriWaste Paper Industry
92
AgriWaste Paper Industry
93
AgriWaste Paper Industry
94
AgriWaste Paper Industry
95
AgriWaste Paper Industry
96
AgriWaste Paper Industry
97
AgriWaste Paper Industry
98
AgriWaste Paper Industry
99
AgriWaste Paper Industry
100
AgriWaste Paper Industry
101
AgriWaste Paper Industry
102
AgriWaste Paper Industry
103
AgriWaste Paper Industry
104
AgriWaste Paper Industry
105
AgriWaste Paper Industry
106
AgriWaste Paper Industry
107
AgriWaste Paper Industry
108
AgriWaste Paper Industry
109
AgriWaste Paper Industry
110
AgriWaste Paper Industry
111
AgriWaste Paper Industry
112
AgriWaste Paper Industry
113
AgriWaste Paper Industry
ENVIRONMENTAL STUDY
WASTEWATER TREATMENT PLANT
To ensure that plants discharged are within acceptable quality, a
wastewater treatment plant comprised of primary and secondary biological
treatments stages is operated at 24 hours a day, 7 days a week.
The proposed wastewater treatment system basically consists of primary
and secondary treatment.
Primary treatment includes the upgrading of existing facilities to improve
solids collection and chemical treatment with clarifier as solid separator unit. Bulk
of the wastewater is being is being generated by the economy filter mated rate of
25 m3/hr. At present set up, wastewater from this source is served by settling
tank prior to its discharge. To improve the collection of entrained fibers from this
particular source for possible re-use in the process, this existing tank was
upgraded to provide for settling chambers.
The final discharge from this settling chamber is to be combined with the
rest of the discharges from other minor source points in the manufacturing
process and will be diverted to an equalization tank/sump pit by gravity.
In the equalization tank a coagulant chemical is added to help coagulate
fine solids into larger particles. Then the wastewater is pumped to the top of the
central steel column, where flocculant is injected and particles agglomerate to
form larger flocs.
The clarifier is equipped with surface and bottom scrapers driven by a
gear motor. The bottom unit scrapes off the settled sludge at the bottom of the
clarifier to the conical bottom for withdrawal. A sludge pump is used to withdraw
the solids in the conical bottom for dewatering to screw press.
The clarified effluent to prevent floating particles from being carried by the
effluent (floating solids are not expected but if occurring, the baffles will limit the
particles). From here, the effluent passes through the overflow weirs that are
114
AgriWaste Paper Industry
attached to the concrete effluent channel. The overflow weirs are installed to
ensure an even overflow of water to the channel.
The secondary treatment shall employ an aerobic Batch type Activated
Sludge System with BOD reduction efficiency of 95-98%. The clarified
wastewater from primary treatment will flow by gravity to a holding tank with
hydraulic retention time of (5) hours.
From this tank, wastewater shall be
pumped to the main process tank for biological treatment. The Fill, React/Aerate,
Settle, Decant cycle time at the Main Process Tank will take 12 hours to
complete.
Sludge shall be generated from both primary and secondary treatment. All
generated sludge shall be pumped into the inlet of the screw press and shall be
carried to the outlet via a rotating screw conveyor. The screw conveyor is
designed such that the volume decreases towards the outlet. As sludge is carried
to the outlet, the sludge is compressed and water is pressed out of the sludge in
the wet slotted screens. The sludge then exists the other side of the screw press
at 15% dryness. Water drained from the screw press is returned to the clarifier.
115
AgriWaste Paper Industry
ENVIRONMENTAL IMPACT ASSESSMENT
INITIAL ENVIRONMENTAL EXAMINATION REPORT
For
MANUFACTURE OF BOND PAPER FROM CORN STOVER
Project Title
A.
GENERAL INFORMATION
Our project location will be located at Santiago City, Isabela. Santiago
City is a first class city and now on the road to highly urbanize status,
Santiago City is a metropolis with 1,160,721 inhabitants comprised of 37
barangays, the city is blessed with an almost equal distribution of urban
and rural areas. This explains perhaps Santiago City viability in terms of
industrialization based on a stable agricultural base.
Strategically located in the heart of the province of Isabela,
approximately 328 kilometers northeast of Manila, the city covers a total
land area of 255 square kilometers. The city held tremendous promise, not
only in its natural resources but also in its potentials in agri-based
industries which help sustain its vital role in agricultural production.
B.
PROJECT DESCRIPTION
1.
Project Ownership: Corporation
2.
Project Site:
2.1.
Land
2.1.1. Total Land Area:
4,166.70 m2
2.1.2. Land Area to be occupied:
3. Population (1995):
3,062.95 m2
1,160,721
116
AgriWaste Paper Industry
C.
INDUSTRY DESCRIPTION AND PRACTICES
Pulp and paper are manufactured from raw materials containing
cellulose fibers, generally agricultural residues. In developing countries,
about 60% of cellulose fibers originate from non-wood raw materials such
as Corn stovers.
Manufactured pulp is used as a source of cellulose for fiber
manufacture and for conversion in the paper and cardboard.
The manufacture of pulp for paper and cardboard employs mechanical
including thermo chemical and chemical methods. Mechanical pulping
separates fiber by such methods as disk abrasion and billeting. Thermo
mechanical pulps, which are used for making products such as
newsprints, are manufactured from raw materials by the application of
heat, in addition to mechanical operations.
Chemical pulps are made by cooking (digesting) the raw materials
using the Kraft (sulfate) and sulfite processes. Kraft processes produce a
variety of pulps used mainly for packaging and high strength papers and
boards. Rice straw are cooked with caustic soda to produce brown stock
which is then washed with water to remove cooking (black) liquor for the
recovery of chemicals and energy.
Mechanical pulp can be used without bleaching to make printing
papers for applications in which low brightness is acceptable – primarily,
newsprint.
C.1.
Waste Characteristics
The significant environmental impacts of the manufacture of pulp
and paper result from pulping. In some processes, sulfur compounds
and nitrogen oxides are emitted to the air, and organic compounds,
nutrients are discharged to the wastewater.
117
AgriWaste Paper Industry
C.1.a. Air Emissions
Pulping process, such as the mechanical and thermo mechanical
methods, generate significantly lower quantities of air emissions.
Steam and electricity-generating units using coal or fuel oil emit fly
ash, sulfur oxide and nitrogen oxides. Coal burning can emit fly ash at
the rate of 100 kg/t of ADP.
C.1.b. Solid Waste
The principal solid wastes of concern include wastewater treatment
sludges (50 – 150 kg/t of ADP). Solid materials that can be reused
include waste paper, which can be recycled, and bark, which can be
used as fuel. Lime sludge and ash may need to be disposed of in an
appropriate landfill.
D.
Pollution Prevention and Control
The unchlorinated material is essentially black liquor that has
escaped the mill recovery process. Some mills are approaching 100%
recovery. Industry developments demonstrate that total chlorine-free
bleaching is feasible for many pulp and paper products but cannot
produce certain grades of paper.
The adoption of these modern
process developments, wherever feasible, is encourages.
118
AgriWaste Paper Industry
Pollution
prevention
programs
should
focus
on
reducing
wastewater discharges and on minimizing air emissions.
Process
recommendations ma include the following:
Use energy-efficient pulping process wherever feasible.
Acceptability of less bright products should be promoted.
For less bright products such as newsprint, thermo
mechanical processes and recycled fiber may be
considered.
Minimize the generation of effluents through process
modifications and recycle wastewaters, aiming for total
recycling.
Reduce effluent volume and treatment requirements by
using dry instead of wet debarking; recovering cooking
chemicals by recausticizing the smelt from the recovery
furnace; and using high-efficiency washing and bleaching
equipment.
Minimize unplanned or nonroutine discharges equipment
failures,
human
error,
and
faulty
maintenance
procedures, by training operators, establishing good
operating practices, and providing sumps and other
facilities to recover liquor losses from the process.
Minimize sulfur emissions to the atmosphere by using a
low-odor design black liquor recovery furnace.
Use energy-efficient processes for black liquor chemical
recovery, preferably aiming for a high solid content (say
70%).
E.
Target Pollution Loads
Implementation of cleaner production processes and pollution
prevention measures can yield both economic and environmental
benefits.
119
AgriWaste Paper Industry
For emissions, the target is 1.5 NOx per ton for both kraft and
sulfite processes; for mechanical and chemimechanical process used in
newsprint manufacture, 260 nanograms per joule (ng/J) of NOx for coal;
130 ng/J for oil; and 86 ng/J for gas used as fuel.
Wastewater generation rates should not exceed 50 m3/t of ADP,
and levels of 20 m3/t of ADP (for product) should be targeted. For paper
mills, effluent discharges should be less than 5 m3/t of ADP.
F.
Treatment Technology
F.1 Wastewater Treatment
Wastewater
treatment
typically
includes
(a)
neutralization,
screening, sedimentation, and flotation/hydrocycloning to remove
suspended solids and (b) biological/ secondary treatment to reduce the
organic content in wastewater and destroy toxic organics.
The wastewater first undergoes a treatment by passing through a
screen, will screen out the coarse materials. After screening, the
wastewater shall undergo flotation, which will separate the light-density
materials; then it will enter a flow equalization tank, which will regulate
the pH of wastewater and its flow rate. The treated wastewater is then
pumped to a sedimentation tank that will help settle down large particle.
To cope with the increasing wastewater volume due to increase in
the pulp production, the treatment facility will also be upgraded.
The waste fibers that have been separated from the wastewater will
be sold to companies that treat the sludge of paper industries and the
clarified water is free to flow into the river.
Table 5.1 Effluent Standards1
Color
1
PCU
150
DENR Administrative Order 35, Table 2A: Effluent Standard
120
AgriWaste Paper Industry
Temperature
Ph
COD
Settleable solids
BOD5
TSS
TDS
Surfactants
Oil/grease
Phenolic subs.
Total coliform
G.
o
C rise
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
mg/L
MPN 100mL
3
6.5 – 9
100
0.5
50
70
1000
5.0
5.0
0.1
10000
Emissions Guidelines
Emissions level for the design and operation of each project must
be established through the environmental assessment (EA) process on
the basis of country legislation and Pollution Prevention and Abatement
Handbook.
The guidelines are expressed as concentration to facilitate
monitoring. Dilution of air emissions or effluent to achieve these
guidelines is acceptable.
All the maximum levels should be achieved for at least 95% of the
time that the plant or unit is operating, to be calculated as a proportion of
annual operating hours.
Liquid Effluents from New Pulp and Paper Manufacturing
Parameter
PH
COD
AOX
Maximum value
6-9
300 mg/l and 15 kg/t for kraft and
CTMP pulp mills; 700 mg/l and 40 kg/t
for sulfide pulp mills; 10mg/l and 5 kg/t
for mechanical and recycled fiber pulp;
250 mg/l for paper mills
40 mg/l and 2 kg/t (aim for 8 mg/l and
121
AgriWaste Paper Industry
0.4 kg/t for retrofits and for 4 mg/l and
0.2 kg/t for new mills) and for 4 mg/l for
paper mills
H.
Monitoring and Reporting
Frequent sampling may be required during start-up and upset
conditions. Once a record of consistent performance has been
established, sampling for the parameters listed in these documents
should be as described below.
Monitoring of air emission for opacity (maximum level of 10%)
should be continuous; daily monitoring should be conducted for
hydrogen sulfide and annual monitoring for other pollutants. Liquid
effluents should be monitored for the listed parameters at least daily, or
more often when there is a significant process change.
Monitoring data should be analyzed and reviewed at regular
intervals and compared with the operating standards so that any
necessary corrective actions can be taken. Records of monitoring results
should be kept in an acceptable format. The results should be reported
to the responsible authorities and relevant parties, as required.
I.
ENVIRONMENTAL IMPACT ASSESSMENT
Santiago City is our project location. The area is not erosion prone.
There is no existing natural hazardous in the area (landslide, subsidents).
There is no project beside or near the shore line. Magat River and Diadi
River are the water bodies that you can found beside or near the
shoreline. There are few trees within the project site. It will be transferred
to another place or we will plant trees in replacement of the trees cleared
for construction of our plant.
We do not pose any threat to Magat River and Diadi River because
we have our own wastewater treatment.
There are also no vegetation clearing, no air pollution produce from
the equipment installed.
122
AgriWaste Paper Industry
There will be an increase in economic activity in the area for we will
be hiring employees living near the vicinity.
The cultural norms or morals and lifestyle of local inhabitants will
not be affected by the project.
ENVIRONMETAL POLICY
AgriWaste Paper Industry has defined an environmental policy with the
principles of managing the way in which it runs its business to minimize
environmental impacts and to become certified by the ISO 14001
(Environmental Management System), the company set the following
environmental policy:
AgriWaste Paper Industry strives to manufacture quality bond paper
that utilizes agricultural wastes which complies to the standard
environmental
regulations
set
by the
DENR
(Department
of
Environment and Natural Resources)
Agriwaste Paper Industry aims to continuously improve environmental
performance and our company is committed to minimize our
environmental impact.
123
AgriWaste Paper Industry
AgriWaste Paper Industry is committed to follow all the requirements
in relation with the environmental protection, and to strive to meet all
the regulatory and legislative laws which comply with the local and
international standard.
AgriWaste Paper Industry would provide document objectives, outline
of the process and responsibilities, manuals, action plans of the
company and its procedure to employees and other members of the
company to become aware of the environmental concerns of the
company.
AgriWaste Paper Industry will create a website of the company which
will provide information’s open to the public. Also, distribution of free
manuals and pamphlets to the people visiting our company.
MATERIAL SAFETY DATA SHEET (MSDS) OF BOND PAPER
SECTION #1 — Hazardous Ingredients/Identity Information
TRADE NAME: AgriWaste Paper Industry
OSHA PEL ACGIH TLV Other Limits Recommended %
This product contains no hazardous or toxic substance as defined in 29
CFR 1910.1200, and is considered to be an article as defined in this same
reference.
SECTION #2 — Physical/Chemical Characteristics
Boiling Point N/A
Specific Gravity (H2O=1)- 0.6-0.7
Vapor Pressure (mm Hg) - N/A
124
AgriWaste Paper Industry
Melting Point -N/A
Vapor Density (AIR=1) - N/A
Evaporation Rate –N/A
Solubility in Water :> 0.5% 1 hour at room temperature
Appearance and Odor: No odor.
SECTION #3 — Fire and Explosion Hazard Data
Flash Point (Method Used):N/A
Flammable Limits: Approx 450° F
LEL: N/A
UEL: N/A
Extinguishing Media: Water
Special Fire Fighting Procedures: N/A
Usual Fire and Explosion Hazards: N/A
N/A = Not Applicable/Not Available
SECTION #4 — Reactivity Data
Stability: Unstable
Incompatibility (Materials to Avoid): Strong acids, alkalies, oxidizing agents
Hazardous Decomposition or Byproducts: CO, CO2 as combustion products
Hazardous: Polymerization May Occur
Conditions to Avoid: N/A
Will Not Occur: X
SECTION #5 - Health Hazard Data
Route(s) of Entry: N/A
Inhalation: N/A
125
AgriWaste Paper Industry
Skin: N/A
Ingestion: N/A
Health Hazards (Acute and Chronic): N/A
Carcinogenicity: N/A
OSHA Regulated: N/A
SECTION #6 - Precautions for Safe Handling and Use
Steps to be Taken in Case Material is Released or Spilled: N/A
Waste Disposal Method: Incinerate or landfill in accordance with local, state
or federal regulations
Precautions to Be Taken in Handling and Storing: N/A
DISCLAIMER:
Although reasonable care has been taken in the preparation of this document,
we extend no warranties and make no representations as to the accuracy or
completeness of the information contained therein, and assume no
responsibility regarding the suitability of this information of the user’s intended
purposes or for the consequences of its use. Each individual should make a
determination as to the suitability of the information for their particular
purpose(s).
126
AgriWaste Paper Industry
127