Optimization of Fiber Properties
Using Single Pass Refining v/s
Recirculation- A Case Study
Yash Papers Ltd.
• Yash Papers established in the year 1981 and is located in
Faizabad, Uttar Pradesh
• We are agro based and use bagasse, wheat straw, gunny
bags and a portion of softwood as a raw material. The
production capacity of the plant is 39,100 MT per annum
• We have three MG paper machine with capacity of
 PM 1- 30 MT/day
 PM 2- 30 MT/day
 PM 3- 70 MT/day
• We have a Recovery Boiler of 140 MT Dry Solids/day
capacity and Power Plant of 6 MW capacity.
• We make specialty and packaging grades of paper.
Objective
To optimize the fiber properties
To produce a paper with enhanced fiber
properties and hence value addition to
existing product basket
To reduce energy consumption and long fiber
consumption & hence reduction in cost of
production
Approach
• To achieve better fiber strength properties we
modified & optimized our refiner operations
• Installation of online measurement & control
systems and automation
• Consistency optimization
• Flow Optimization
• Different grades of Long Fiber Optimization
TDR Overview
TDR Control Panel
Recirculation
0SR
15
20
25
48
Recirculation
Time
3.30 hrs.
4 hrs.
5 hrs.
8 hrs.
Cy%
4.2
4.2
4.2
4.2
Burst Factor
16.89
18.38
35.01
40.41
Tear Factor
103.70
137.03
140.86
104.22
Load 21”/17”
(Amp)
180/160
180/160
180/160
180/160
Consistency Optimization
Consistency Trial
Consistency%
4.5
4.2
3.9
3.5
3.3
Burst Factor
29.4
26
24.4
22.9
35.8
Tear Factor
196.9
185
187.5
191.5
190.4
Observation
• The Burst Factor increased by reducing the
consistency of the pulp without affecting
other properties
FLOW OPTIMIZATION
Flow@ 3.3% Consistency
20 m3/hr
After 21”
Refiner
30 m3/hr
After 21”
Refiner
40 m3/hr
After 21”
Refiner
50 m3/hr
After 21”
Refiner
MT/hr
0.66
0.9
1.3
1.6
0SR
21
20
20
19
Flow
Initial
• Flow @ 3.3% Consistency
Burst Factor
11.8
42.9
39.6
37
35.8
Tear Factor
150.4
173.7
200
168.6
168.1
Refiner load
21”/17”
(Amp)
180/160
90/91
120/100
160/155
180/163
Pressure
(kg/cm2)
1.1
2.8
2.4
2.1
1.9
Flow@ 3.7% Consistency
20 m3/hr
After 21”
refiner
30 m3/hr
After 21”
refiner
40 m3/hr
After 21”
refiner
50 m3/hr
After 21”
refiner
MT/hr
0.7
1.1
1.5
1.9
0SR
20
18
17
15
Flow
Initial
Burst Factor
9.2
36.3
33.8
31
22.9
Tear Factor
101.4
204.7
206.3
191.9
173.2
Refiner load
21”/17”
(Amp)
180/160
85/92
120/126
165/136
170/164
Pressure
(kg/cm2)
1.2
2.5
2.3
1.9
1.8
Flow @ 3.9% Consistency
20 m3/hr
After 21”
Refiner
30 m3/hr
After 21”
Refiner
40 m3/hr
After 21”
Refiner
50 m3/hr
After 21”
Refiner
MT/hr
0.8
1.2
1.6
2.0
0SR
18
16
16
15
Flow
Initial
Burst Factor
9.9
33.1
28.6
27.6
24.4
Tear Factor
91.2
239.4
202.8
187.3
178.5
Refiner load
21”/17”
(Amp)
180/160
82/90
107/100
133/125
150/160
Pressure
(kg/cm2)
1.1
2.8
2.4
2.1
1.9
Flow @ 4.1% consistency
20 m3/hr
After 21”
Refiner
30 m3/hr
After 21”
Refiner
40 m3/hr
After 21”
Refiner
50 m3/hr
After 21”
Refiner
MT/hr
0.8
1.2
1.6
2.1
0SR
19
18
17
15
Flow
Initial
Burst Factor
10.7
35.3
34.6
32
26
Tear Factor
105.4
200
192.6
176.2
157.5
Refiner Load
21”/17”
(Amp)
180/160
100/104
120/126
130/132
140/137
Pressure
(kg/cm2)
1.2
2.4
1.9
1.8
1.5
Flow @ 4.5% Consistency
20 m3/hr
After 21”
Refiner
30 m3/hr
After 21”
Refiner
40 m3/hr
After 21”
Refiner
50 m3/hr
After 21”
Refiner
MT/hr
0.9
1.4
1.8
2.3
0SR
17
17
16
15
Flow
Initial
Burst Factor
9.7
31.7
30.3
29.4
25.6
Tear Factor
106.2
191.5
213.3
196.9
154.3
Refiner Load
21”/17”
(Amp)
180/160
180/100
120/124
135/137
140/136
Pressure
(kg/cm2)
1.1
2.5
2.1
1.8
1.5
Trends
@ 20 m3/hr
50
40
BF
30
BF
20
10
0
3.3
3.7
3.9
4.1
4.5
@ 30 m3/hr
45
40
35
30
25
20
15
10
5
0
3.3
3.7
Cy%
3.3
3.7
Cy%
4.1
4.5
Cy%
@ 40 m3/hr
40
35
30
25
BF
20
15
10
5
0
3.9
3.9
@ 50 m3/hr
40
35
30
25
BF
20
15
10
5
0
4.1
4.5
3.3
3.7
3.9
Cy%
4.1
4.5
Observation
• At any particular consistency, strength
property is increasing with reduced flow rate
level
• At any particular flow rate, it is observed that
with decreasing stock consistency strength
properties are better
Grades Selection & optimization
of Long Fiber
Burst Factor @ 3.3% Consistency
Flow (m3/hr)
Grade 1
Grade 2
Grade 3
20
44.7
35.2
70.5
30
41.2
33.4
54.8
40
39.0
32.1
53.1
Burst Factor @ 3.9% Consistency
Flow (m3/hr)
Grade 1
Grade 2
Grade 3
20
36.3
32.1
68.4
30
33.9
30.6
50.7
40
32.2
29.6
39.2
Burst Factor @ 4.2% Consistency
Flow (m3/hr)
Grade 1
Grade 2
Grade 3
20
34.0
35.0
66.1
30
36.6
30.6
50.8
40
37.7
28.4
42.5
Trends
80
70
At consistency 3.9 %
At Consistency 3.3%
80
70
70.53
60
50
40
BF
68.36
60
44.69
36.21
30
54.76
53.06
41.23
33.41
39
32.1
50.74
50
BF
40
36.3
32.1
30
33.9
30.6
39.21
32.2
29.6
20
20
10
10
0
0
20 m3/hr
20 m3/hr
30m3/hr
30m3/hr
40 m3/hr
At consistency 4.2%
70
66.12
60
50.8
50
BF
40
30
35.02
34
36.65
30.56
42.46
37.75
28.41
20
10
0
20 m3/hr
30m3/hr
40 m3/hr
Grade 1
Grade 2
Grade 3
40 m3/hr
Observation
• Grade 3 of long fiber shows better strength
properties as compared with other two grades
COST BENEFIT
Cost Benefit
• By using Single pass refining we achieved a
reduction of 1% long fiber in the papermaking
resulting in a saving of Rs. 1.18 crore
• The energy consumption observed decreased in
single pass refining as compared to recirculation
• The paper produced through single pass refining
shows better strength properties as compared to
recirculation
• The paper thus produced added value by
increased NSR
Cost Benefit by Softwood Reduction
Serial No.
Parameters
September
October
With Circulation
Single Pass
1
Softwood
15%
14%
2
Bagasse Tear
42.0
41.6
3
Bagasse Burst
Factor
16.07
15.82
4
Savings
15.0-14.0 = 1%
5
Softwood
Saving/Month
18 Tons/Month
6
Saving/Year
216 Tons/Year
7
Cost
216*55000 = 1.18 Crore
Running Load
Refiner running Load Data
Refiner
Current (Amp)
Power (Kwhr)
21”
180
109.73
17”
160
97.54
Power Saving
Serial No.
Particulars
Recirculation
Single Pass
1
Running Hours
13.25
6.97
2
Batch Size
50 m3 @ 4.2cy%=
2.10 MT
30 m3/hr. @ 3.3
cy%= 0.99 MT
3
Recirculation Time
4 hrs.
4
Net Output
2.14*(13.25/4)=
6.95 MT
0.99*6.97= 6.9 MT
5
Power Consumption/Day
(Kw/Day)
2746.32
1444.71
6
Power Consumption/year
(Kw/Year)
906285.6
476754.3
7
Power Consumption
Saving/Year (Kw)
429531.3
8
Cost Saving (Per Unit CostRs.3)
Rs. 12,88,593
THANK YOU