Paper plays a crucial role in our day-to-day lives. The paper industry in India contributes about 1.6% of the total global paper production with an approximate turnover of 250000 Million. The first-ever machine-made paper was manufactured in India in 1812 when there were only 15 paper mills. Presently, India has approximately 800 paper mills manufacturing paper bags, handmade paper boxes, paper albums, etc., exporting paper products worth 4000 million worldwide. As per a report by the Indian Paper Manufacturers Association (IPMA), the per-capita paper consumption in India is estimated to be 13 kg. The paper industry offers employment to a significant population, and the paper and paper products industry may grow to a market of $ 13.4 billion by 2024.
The Manufacturing Process from Pulp to Paper:
Paper processing includes various operational stages before the paper is deemed ready to be exported to markets. Paper processing mainly requires water, chemicals, energy, and cellulose (extracted from softwood or wood chips). Debarking of the wood logs is essential before forming them into wood chips. The main stages of the paper processing are as follows:
- Pulp formation:
The wood chips are transferred in a high-pressure vessel termed a digester. Over here, the wood chips are cooked and boiled with a chemical solution that is eventually dissolved and formed into a pulp. The pulp is filtered, and if required, bleached before it sending it for further process.
- Beating:
Once the pulp is formed, the process of beating takes place. As the name suggests, the pulp is beat along with adding other filler materials and additives. It impacts the quality of the paper.
- Processing Pulp to Paper:
In this process stage, the pulp is squeezed through a series of rollers by feeding it to automated machines that form it as paper. The beating process is followed, by a press section that consists of pressing the paper between steam-heated cylinders that removes the excess water from the paper.
- Finishing Products:
The resultant paper is rolled in reels that would be moved for further processing depending on the paper product to be manufactured.
Why are Steam Boilers Important in the Paper Industry?
Steam is pivotal in the paper industry for the process of drying the paper, energy requirement, and the cooking of wood chips in the digester. Some of the essential requirements of steam in paper processing are,
Uniform Heating:
The utilization of rolls in paper processing requires it to be heated internally with steam. Therefore, it is essential to maintain an even temperature across the surface of the rolls for uniformity and high-quality products. Steam is an ideal choice as it condenses and distributes heat evenly.
Steam Carries Ample Heat:
Most processing plants require a considerable amount of energy, and the paper industry is no different. One of the optimal ways to carry energy for processing operation is through latent heat in steam. For instance, 150 psig of saturated steam carries around 3.5 times heat content, and the energy is released as soon as the steam comes in contact with the internal surface of the roll.
Precision in Steam Temperature:
As temperature demand increases or the higher grade papers are manufactured, higher pressure and temperature are needed. The plant operators can control the pressure and set the steam temperature inside the roll. The saturated steam maintaining the same temperature at a given pressure allows the operators to control the pressure and steam temperature as required.
Efficient Process Operations:
Steam boilers are highly efficient for generating steam and power for processing purposes. The generated steam is operated in an insulated, closed-loop system. Hence, steam boilers are efficient and reliable for the process industry’s operations.
Challenges in Paper Industry:
Expensive Raw Materials:
The raw material for paper processing mainly includes wood fiber which is high in cost and difficult to procure.
High Power Demand:
Paper mills require a high amount of power to function efficiently. Nowadays, paper processing plants have switched to power generation boilers that aid them in generating both steam and electricity.
Deforestation and Environmental Harm:
The cutting down of trees to acquire wood for process operations results in deforestation. It disturbs the environmental cycle and accelerates the pollution level.
Boilers in Paper and Paper Products Industry:
Steam boilers in the paper industry are used for generating steam and power required in the processing plants. Steam is essential for operations such as heating of chemicals, heating rollers, etc. Because of the paper industry requiring a high amount of steam; it is important to choose efficient and durable steam boilers. Boilers with reciprocating grates are best suited for the effective combustion of fuels like wood chips, wood logs, sawdust, and agro-waste used in paper process plants.
Rakhoh Boilers have been manufacturing highly efficient and reliable steam boilers for more than 38 years. Rakhoh’s boiler models such as Combo X, Membrane X, and Solid Fuel Bi-Drum are preferred by some of the leading paper mills in India.