Breaking production records and advancing sustainability

Valmet TwinRoll Presses successfully integrated into the fiberline.  

In JK Paper´s fiberline and lime kiln relocation project, one new TwinRoll press was delivered, and some equipment was relocated from the Rayagada plant. For example, two TwinRoll presses, washers, screens, MC pumps and scrapers. Those were reconditioned with help from Valmet and reused in the fiberline.

Overcoming challenges and reaching targets

“We faced some start-up issues with fluctuations in the lime kiln, but with Valmet’s help, we achieved our target production of 220 metric tonnes within three months. We also installed a burner that allows us to use furnace oil, pet coke and methanol. Initially, the production cost was high, but after installing the burner, it decreased, says Mr. Kartik Patel, Senior Manager Soda Recovery Process at JK Paper – CPM, Songadh.

The retrofitted lime kiln has the capacity of 220 tonnes of burned lime per day and is equipped with a burner to burn furnace oil, pet coke and methanol.

“The new design capacity of the fiberline and unbleached section is 500 tonnes per day and the bleached section is 450 tonnes per day. Both targets have been achieved with the help of Valmet. We plan to upgrade the capacity to 550 tonnes per day and are already discussing this with Valmet to identify bottlenecks in the current process,” says Mr. C. Muthaiyan, General Manager Instrumentation and Automation at JK Paper’s Songadh facility.

New production record with good cooperation

“We have broken a record in our JK Paper fiberline, it is 428 tonnes per day of continuous basis within a month. This is very appreciated and thanks to Valmet and our team that got the plant established within such a short period of time. We are satisfied with the cooperation between JK and Valmet all from design of product to the quality,” says Muthaiyan.

There were some challenges in the lime kiln mechanical performance, which were solved together during the project. “I appreciate that Valmet supports us whenever we need assistance. We call and Valmet engineers are there to help,” he continues.

Advancing sustainability with new initiatives

Water plays a crucial role in the pulp and paper industry, which is increasingly adopting sustainable and circular practices. As per the guidelines from the Central Pollution Control Board of the Government of India, every paper mill in the country is required to recycle water, ensuring that no effluent water is discharged into nearby water bodies.

The mill has several ongoing projects to reduce the water consumption.  

“We have had several projects to reduce the water consumption in the fiberline by, reusing, recycling and reduce wastage. For example, in the last post oxygen stage we only use secondary condensate. We have also installed heat exchangers and a hot water tank in the unbleached section and now we can reduce about 752 to 800 metric tonnes of water per day,” Muthaiyan explains.

A methanol plant was installed and started up in April 2024. “The NCG gases, byproduct from the evaporation plant that were earlier emitted to the atmosphere, are now captured and converted into methanol by condensation, fired in the lime kiln, and used as additive fuel, which also reduces our fuel costs. Considering the environmental point of view, it worked very well, Patel concludes. 

Text: Kerstin Eriksson