agro residue_paper industry

7/28/2019 Agro Residue_Paper Industry

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4th Cess 'Iraininq (J lrogrammeUtilization of Agro-Residue Fibres

in Indian Paper Industry

Sponsored 6y

Deoeiopement Council for (Jlulp,CP apercSljflC ied Industry

:Ministry of Commerce cSlIndustry(jovt. of India


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4thCessTraining Programme

Utilization of Agro-Residue Fibresin Indian Paper Industry

atChandigarh9th - 12th May 2005

Oraanisea 6]

c f30c lm ~c!l ~ CPleJIJ1 ~enoI ~Central Pulp & Paper Research InstituteA N IS O 90012000 IN S TIT UT IO N

In pursuit of cleaner production, resource conservation c 1 , qua[ity excellence


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~ ~ \Ri'rrr -q-~(31~t1I[TICfl ~ 3i'R fTq$1 fctl:rrrr)\RlTrT . , - q .: r , ~ ~990099Ministry of Commerce & Industry

(Deptt. of Industrial Policy and Promotion)Udyog Shawan, New Delhi-11 0011

S. J AGADEESANJ Oint Secretary

Phone.3012750Fax .3013655

FOREWORDThe deployment of skilled and trained manpower In Indianpaper .industry IS relatively lower as compared to the paperindustry in the developed countries. Looking into the remarkabletechnological advancements and for their absorption & adoption intoour conditions, there is a need for skilled & trained manpowerin the paper industry. Oneof the objectivesof "Continuing Education& Training Programmes" under the Cess funded schemes isto create an awareness on the technological needs & developmentsin technologies around theworld. In fact, forest based pulp and papermlls have the advantage of better technologies and are well equippedwith skilled & trained manpower. The Agro-based pulp and papermllsarehavingrelativelylowertrained & skilledmanpower. I remember,when we started this continuing education & training programmesfor the pulp and paper industry, therewas an over-whelmngresponsein three of the earlier training programmes completed, and morethan 100 technical personnel had an opportunity to get the exposuretothetechnological advancements inpulpandpaper mlls.I am sure that this specific training programme on. "Utilization orAgro-Residue Fibres In Indian Pulp& Paper Industry" scheduled tobeheld at Chandigarh from 9th to 12th May, 2005 coveringwide range of topics is goingto beahighly relevant for the agro-basedpulp and paper mlls. .The agro-based pulp and paper mlls, which are presentlycontributing around 32%of the total paper production, will continueto play an important role in augmenting the demand of paperand paper products. Inviewof the emergingenvironmental and qualityrequirements, there is a need for induction of modern technologiesinagro-based pulpandpapermllsfortheir healthy growth.

cont'd.....p/2


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continuation sheet...2

I am glad that this 4th training programme on Utilization OfAgro-Residue Fibres In Indian Pulp & Paper Industry"has been designed specificallyfor-the agro-based pulp and paper mllscovering wide range of subjects such as;- raw materials handling,storage & up gradation; pulping, bleaching & washing practices,energy & environmental management, etc., and I am surethat this will help the senior technical personnel fromthe agro-basedpulp and paper mlls in absorption & adoption of the moderntechnologies will also help to educate these mlls in achievingcost effectiveproductionwithan improved qualitystandards.I compliment CPPRI for having successfully organized these trainingprogrammes under the Cess funded schemes on various topicsrelevant totheIndianpaper industry.I would also like to thank all the faculty members for agreeing tospare their valuable timein sharing their vast knowledge&experiencesduring thetraining programme.I wish this training programme asuccess. 4-

( S. J AGADEESANCHAIRMANCESSCOMMITTEE(GOVTOF INDIA)


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~aGRI ~crcfttm ct>dl\ll ~HfIIOI H~IOICentral Pulp&Paper ResearchInstitute

AN ISO 9001:2000 INSTITUTIONIII pursuit of cleaner productio. ii resource conservation &quality excellenc ~

An autonomous organisation registered under societies Act under the administrativecontrol of the Ministry of Commerce &Industry (Govt. of India)

Aa...ntedby~ ~Member of the nI A FM L A for , ~QMS *~

A. G. KULKARNIDirector PREFACEThe4th trainingprogrammeon"UtilizationOf Agro-ResidueFibres In IndianPaper Industry" undertheCessfundedsponsoredschemeshasbeenorganizedby Central Pulp & Paper Research Institute(CPPRI) specifically to give anopportunityto theagro-basedpulpandpaper mlls to knowabout the latesttrends in technologies around the world. The agro-based pulp and papermlls will continue to play a pivotal role in Indian paper industry byusing the renewable resources for production of paper and paper products.This training programme has been exclusively formulated keepingin view of the needs of the agro-based pulp and paper mlls.In all there will be 22 Lectures during this 4 days training programmeandtheseLectureswill coverwiderangeof thetopicssuchas:- rawmaterialshandling, storage & up gradation; pulping, bleaching & washingpractices, energy & environmental management and quality etc.Emnent faculty members combinedwith the senior Scientists fromCPPRIwill sharetheirwideknowledgeandexperienceduringthistrainingprogramme.I must compliment CPPRI team led by Dr. Vimesh Bist,Scientist E-I(Training Coordinator) in efficiently organizing thistraining programme, and I am sure that this training programmewill be extremely beneficial for technical personnel from the agro basedpulp andpapermlls.I would also like to thank all the paper mlls for showing theirkeen interest in this training programme organized by CPPRI,and would urge upon all the pulp and paper mlls to take the fulladvantageofthesetrainingprogrammesinfuturealso.I am sure that this training programme will give thetothemll'spersonnel. t:dexposureI wishthistraining programme asuccess.

( Dr.AG Kulkarni )DIRECTOR

POST BOX NO. 174, PAPER MILLS ROAD, HIMMAT NAGAR, SAHARANPUR247 001 (U.P.) INDIATel. Direct (0132) 2727227(0), 2729398(0), (0132) 2727322 (R)Tel. EPABX (0132) 2725317, 2722756, 2727036Cable: CEPPRI, Saharanpur, Fax (0132) 2727387(0), 2721367(R)website:www.cppri.org.in, Email: [email protected]@cppri.org.in.

------- BAS E O FF ICE ----------------N-242, Greater Kailash, Part-I, New Delhi -110 048
mailto:[email protected]@cppri.org.in.mailto:[email protected]@cppri.org.in.


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CONTENTSS.NO L E CT UR E T OPI C PAGE NOGENERA L INTRODUCTION OF NON WOOD FIBRES1 A GRO RESIDUE- A POTENTIA L FIBRE 1SOURCE FOR PUL P & PAPERMANUFACTURING2 ROLE OF NON WOOD PL A NT FIBRE IN 32INDIA N PA PER INDUSTRY3 REL EVA NCE OF NON WOOD PL A NT 39FIBRES IN INDIA N PA PER INDUSTRYM ORPHOL OGY OF NON WOOD FIBRES4 STRUCTURE OF NON WOOD RAW 43M A TERIA LS A ND THEIR IM PA CT ONFIBRE L INE OPERA TIONSRA W M A TERIA L HA NDUNG, STORA GE & UP-GRA DA TION OF NON WOODFIBRES

5 RA W M A TERIA L HA NDL ING A ND 75STORA GE PRA CTICES IN A GRO BA SEDM I L L S6 RAW M A TERIA L UP-GRA DA TION OF A GRO 86.1RESIDUES7 STA TUS OF TECHNOL OGIES IN A GRO 87BA SED M I L L SPUL PING, BL EA CHING A ND WA SHING8 PU L PING AND BL EA CHING 138CHA RA CTERISTICS OF M A JOR A GRORESIDUES9 WA SHING PRA CTICES IN A GRO BA SED 153M I L L S

PA PER M A K ING10 SL IM E CONTROL IN A GRO RESIDUE 157BA SED M I L L S11 NEUTRA L A ND A L K A L INE PA PERM A K ING 172A ND ITS REL EV A NCE TO A GRO RESIDUEPULPS12 QUA L ITY IM PROV EM ENT OPTIONS IN 201AGRO RESIDUE PU L PS


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B LACK L I QUOR CHARECTER IST IC S & CHEM ICA L RECOVERY13 NON WOOD BL A CK LIQUOR 219

CHARECTERISTICS AND REL A T EDPROBLEMS14 A NON CONVENTIONA L CHEM ICA L 227

RECOV ERY INST A L L ATION IN SHREY A NSINSUDTIES L TD - A CA SE STUDY 1995-96

15 BUIL D UP OF NON PROCESS EL EM ENTS 235IN A N A GRO BA SED M IL L A ND THEIRIM PA CT ON CHEM I CA L RECOV ERYOPERATIONS

ENERGY A ND ENV IRONM ENT M A NA GEM ENT16 ENERGY CONSERVA TION 245OPPURTUNITIES IN A GRO BA SED M IL L S17 BIO-ENERGY RECOVERY IN A GRO BA SED 260

M IL LS - A CA SE STUDY18 COLORREMOVA L OPTIONS IN A GRO 277

BA SED M I L L S19 STA TUS OF EFFL UENT PRA CTICES IN 294AGRO BASED PAPER INDUSTRY

TESTING M ETHODS20 ENV IROM NET A L M ONITORING - NEED 310A ND SIGNIFICA NCE OF WA STEWA TER,A IR A ND SOL ID WA STE A NA LY SIS


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4" CESS PROGI


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4th CESS PROGRAMME "UTILIZATION OF AGRO RESIDUE FIBRES IN IINDIAN PAPER INDUSTRY" 9th -12th MAY '05

AGRO RESIDUES - A POT ENT I A L F I BRE SOURCE FOR PUL P &PA PE R MANUF A CT U RI NG

Dr. A. G. K ulkarni,Director,CP PR I , Saharanpur

A bout T he A uthorDr. A.G. Kulkarni, Director Central Pulp& Paper Research Institute (CPPRI)Saharanpur, Uttar Pradesh,India has beenwith the CPPRIsince its inception.He holds a Master degree in Chemistry & Doctorate in BlackLiquorandLigninChemistry. .Dr. Kulkarni has pioneered the research work on Desilication of black liquorwith eventual developmentof mill scale plant, installed at HindustanNewsprintLtd., Kerala and High Rate Bio-methanation of black liquor rich effluent and amill scale unit is successfully operating at Satia Paper Mi"s is anotherachievement of Dr. Kulkarni. His contribution in the area of physicochemical &thermal properties of agro - residue non-woodblack liquors has nowmade itpossible to process this liquor in chemical recovery boilers. He has publishedmore than 300 scientific papers in Indian and International journals. He iswidely traveled in Europe, S. E. ASia,and Australia and has been on severalforeign missionsasUNDP/UNIDO Consultant.His areas of specialization include pulping and bleaching, black liquor-itschemistry & processing,environmentandenergymanagement.Dr. Kulkarniholdsseveral patents-important ones being on desilication of black liquor, thermaltreatment of black liquors and Direct Alkali Recovery System etc. He is amember of several National and International Scientific & Technicalorganizations and also on board of Directors of Paper Mi"s & Researchorganizations


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4th CESS PROGRAMME "UTILIZATION OF AGRO RESIDUE FIBRES IN INDIAN PAPER INDUSTRY" 9th -1 z" MAY '05

AGRO RESIDUES - A POTENTIAL FIBRE SOURCE FOR PULP &PAPER MANUFACTURINGDr.A.G.Kulkarni

The article on "Agro residues - a potential fibre source for pulp & papermanufacturing" discusses the chronological developments in Indian Paper Industry interms of its growth, production level and levels of capacity utilization. The article alsohighlights the status of non-wood fibres in terms of availability, basic inputrequirements and challenges ahead of agro based industries.


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4TH CESS PROGRAMME 'UTILIZATION OF AGRO RESIDUE FIBRES IN INDIAN PAPER INDUSTRY" 9th -iz" MAY '05

ROLE OF NON-WOOD PLANT FIBRE IN INDIAN PAPERINDUSTRY

Dr. A.R. K. Rao,Consultant,Ex. Chairman cumManaging Director,H.P.C. Ltd.(A Govt. of India Enterprises)About The AuthorDr. A,R.K. Rao, Ex Chairman cum Managing Director, Hindustan Paper CorporationLtd. ( A Govt. of India Enterprise) with a brilliant academic career is an engineeringgraduate (B.Tech. Chemical) from Osmania University, Hyderabad (A.P.) and a postgraduate in engineering from Indian Institute of Science, Bangnlore. He stoodSecond in B.Tech. Chemical Engineering exam in the year 1963 in University ofOsmania, Hyderabad. He has the distinction of holding merit scholarship of thesame university during the academic year 1962-63 and of Indian Institute ofScience, Bangalore for three consecutive years from 1963-1966. He holds a Ph. Ddegree in Chemical Engineering from University of Ottawa, Canada(1970). He wasChairman cumManaging Director ,H.P.C.Ltd., from April, 1996 to J anuary, 2001.During his tenure as CMD he also functioned as Chairman of Hindustan NewsprintLtd., Newsprint Nagar, Kerala and Mandya National Paper Mills Ltd., Belagula,Karnataka subsidiary companies of H.P.C.Ltd. Prior to joining as CMD he was withThe Mysore Paper Mills Ltd., Bhadravati, Karnataka from J une, 1993 to March,1996.As an young Engineer he joined The Andhra Paper Mills Ltd., Rajahmundry (A.P.) asChief Chemist in February, 1973 and held this position till December, 1975 and wassubsequently promoted to the post of Superintending Engineer (Planning &Development) in J anuary, 1976 . Prior to attaining the highest position in a Govt.,Enterprise he held various important positions.:. Project Coordinator (UNDP/FAO-GOI Project), New Delhi, February, 1977 to

J une, 1981



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.:. Director (Acting), Central Pulp & Paper Research Institute, Saharanpur, U.P.December, 1980 to June, 1981.

.:. During his tenure in Seshasayee Paper & Boards Ltd., Erode (TN) from June,1981to March, 1993 from the post of Manger (R&D)he rose to the level of VicePresident (Technical) .. Asstt. General Manager (Research & Development & Technical Control),December, 1985 to June, 1986.. Asstt. General Manager (Technical), June, 1986 to March, 1990.:. VicePresident (Technical), April, 1990 to March, 1993.He has more than 45 technical articles to his credit, which have been published invarious National, & International journals of high reputation like TAPPI, APPITA,IPPTA, Pulp & Paper Chemical Engineering Sc., Canadian Journal of ChemicalEngineering etc. He has the distinction of holding important position in varioustechnical associations. He was President (IPPTA), 1998-1999, Vice President(IPPTA in 1996-1997 & President (INMA) in 1997-98 & 1998-99. He was themember of Technical association of Pulp & Paper Industry, U.S.A. and TechnicalAssociation of Australia and NewZealand.Served as National Editor for the technical journal "Pulp & Paper International"from 1990 ~o 1998. Was the Chairman of "Paper & Its Products" (excludingpackaging material) Sectional Committee, CHD15, of BIS, Govt. of India from 1991to 2001. Was member of Indian Delegation to hold discussions regarding TechnicalCooperation in the field of Pulp& Paper Technology with Russian delegation in theyear 1980. Was sponsoredby Govt. of India and FAO of United Nations to visit Pulp& Paper Research Centers ineight European Countries.Was honored by IPPTA on October 13, 2000 in the Zonal Seminar at Jaipur forsignificant contribution and was presented with a memento.. Was also facilitatedfor technical contributions to Indian Pulp& Paper Industry with amemento by "TheIndian Paper Mills association" on February 21, 1992 at Kolkataon the occasion ofGolden Jubilee Celebrations. Participated as faculty in the UNEP workshops on "Environmental aspects of non-wood fibre pulp & paper manufacturing" in China,India & Philippines. He has four best paper awards of IPPTA for the years 1979,1980, 1981& 1985 to his credit.

CENTRAL PULP & PAPER RESEARCH INSTITUTE=================


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4th CESS PROGRAMME "UTILIZATION OF AGRO RESIDUE FIBRES IN INDIAN PAPER INDUSTRY 9th_12th MAY '05

ROLE OF NON-WOOD PLANT FIBRES IN INDIAN PAPERINDUSTRYDr.A.R.K.Rao1.0 INTRODUCTION

.:. Predominant role of Bamboo in the growth of paper industry in India .. The spurt in growth in 1980'~ based on agro-residues .. The increase in production capacity from 1.56 million tonnes in 1980-1981 to 5.63 million tonnes in 1999-2000 .. The present contribution of 29 to 30% of Indian paper production byagro-residues is significant.

2.0 MAIN AGRIRESIDUES UTILISED BY PAPER INDUSTRY1. Bagasse2. Wheat straw3. Rice Straw4. J ute5. Mesta6. Grasses7. Cotton Stalks8. Cotton Linters9. Sunn Hemp.In this presentation, we focus on utilization of bagasse by Indian paperindustry.

3.0 BAGASSE.:. Sugarcane residue .. India is world's largest producer of sugarcane close to 280 milliontonnes..:. Sugarcane development department's spade work to ensure growingof sugarcane by farmers .. Bagasse can also be considered as industrial by-product.

.:. Ready availability.


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4'" CESS PROGRAMME 'UTILIZATION OF AGRO RESIDUE FIBRES IN INDIAN PAPER INDUSTRY 9"'_12'" MAY '05

.:. Easy accessibility .. Surplus bagasse in sugar mills is expected to be available between 6

to 10% of bagasse, depending upon the thermal efficiencies ofbagasse-fired boilers .. Substitute bagasse will be available by replacing the bagasse with

coal or lignite .. Can be stored in the form of bales, stacked to acceptable heights .. Steps. need to be taken to avoid auto combustion. Techniques are

developed .. Alternately, wet bulk storage is practiced. However, yard losses needto be controlled and environmental aspects need to be taken care.

4.0 ANALYTICAL ASPECTS.:. Bagasse constitutes about 32-34% of cane.:. Contains about 50% moisture at the time of generation.:. Contains small quantities of residual sugars depending upon theefficiency of cane crushing mills .. Contains 30 to 32% pith, which has no fibre value, therefore, needs tobe removed to an optimum level..:. Rind fiber contains considerable amount of silica, which hamperschemical recovery operations.

5.0 DEPITHING1. Dry depithing2. Moist depithing3. Wet depithing4. Biological depithingFiber loss in depithing operation restricts the complete removal of pith,therefore, undesirable effects of pith can not be totally avoided.Pith separated from bagasse can be conveniently burnt in boilers, oncemoisture is reduced.



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4th CESS PROGRAMME "UTILIZATION OF AGRO RESIDUE FIBRES IN INDIAN PAPER INDUSTRY" 9'h_1ih MAY '05

6.0 DIGESTION.:. Pandya continuous digesters are used by the large integrated papermills for pulping purposes .. Small mills use spherical digesters with special chemical and rawmaterial mixing arrangement.

7.0 WASHING, SCREENING AND BLEACHING.:. These operations are carried out in a similar way done with bambooand wood pulps, improvising the equipment and operating conditionsto suit the poor drainability of the pulps and responses to bleachingsequences .. S~ock preparation, papermaking and chemical recovery operations arenot covered here, as they will be dealt in detail by other technicalpresentations. However, some unique features of the large integratedmills, practicing bagasse pulping are given comprehensively.

8.0 SESHASAYEE PAPER AND BOARDS LTD.1. Installation of a sugar mill, namely "Ponni Sugars and Chemicals ",with coal fired boilers, adjacent to the paper mill to supply bagasse.2. To encourage formation of lift irrigation-societies,--sparing paper mills -liquid effluent for irrigation and growing sugar cane in the adjacentfields.3. Facilitating "NABARO" to give necessary financial support in the formof loans for laying pipelines and installing pumping facilities.4. To install depithing and baling equipment in the premises of sugar milland to transport the bagasse to paper mill. .5. To carry out research by sponsoring projects to Tamil Nadu agriculturaluniversity to study the effect of irrigating lands with paper mill effluent.and to suggest amendments to soil, if necessary.6. Conducting innovative research, jointly with sugarcane breedingresearch Institute, Coimbatore, to develop cane varieties to yield highfiber content to result in bagasse with higher pulp yields.



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7. Successfully evolved system to monitor stack temperature to avoidauto combustion.8. Using sulphate white liquors for digesting bagasse also.9. Practicing chemical recovery with combined kraft black liquors of woodand bagasse.10.Making provision for separate washing screening, bleaching andrefining lines for bagasse and wood pulps.11.Made provision for blending bagasse and" wood pulps in differentproportions suiting the product requirements.12.Treated combined liquid eff luent is supplied to lift irrigation societies forrising sugarcane.

,-------9.0---THE-MYSOREPAPER MILLS LTD. (MPM)1. MPM installed a sugar mill in its own premises under the samemanagement.2. Erected necessary equipment to blow bagasse from sugar mill directlyto paper mill's depithing section.3. Made provision to divert the bagasse to the baling plant, which isinstalled in sugar mill, to meet with the exigencies arising out of failuresin the blowing operations. \4. Special area is allotted to stack bagasse bales in the yard5. Arrangements are made to blow pith to adjacent boiler house forburning.6. Oepithed bagasse is pumped to the wet bulk storage yard in the formof slurry; piling operations are carried out using a bull dozer and a payloader.7. Provision has been made to retrieve the bagasse to feed to thecontinuous digester of J apanese make.8. Subsequent operations of washing, screening and bleaching arecarried out separately in the old pulp mill section of the plant.9. Chemical recovery operations are carried out with combined black

liquors of wood and bagasse pulping.



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10.Bagasse pulps are mostly used in the manufacture of cultural varietieson the old machines. In emergent situations, it is used to the extent of5% inmanufacture of newsprint.11.Required power, water and steam are supplied to sugar mill by theutility sections of the paper mills.12.Combined sugar mill and paper mill liquid effluents are treated in acommon treatment plant.

10.0 TAMIL NADU NEWSPRINT AND PAPERS LTD. (TNPL)1. TNPL procures bagasse from sugar mill with an arrangement to supplysteam to them by installing and operation coal fired boilers at sugar millsites.2. Bagasse from sugar mills is transported using large tipper trucks in\Idose form.3. Bagasse is stored in the wet bulk storage form in a large yard.4. Depithing arrangement is also made at the paper mill.5. Depithed bagasse is stacked using boom stackers.6. Retrieving of bagasse is done using belt conveyer systems to feed tothe digester7. TNPL makes chemical and mechanical pulps from bagasse8. Wood and bagasse pulps are processed separately in washing,screening and bleaching operations.9. TNPL has the credit to be the first mill to produce successfullymechanical pulps from bagasse to be used in newsprint.10.Bagasse mechanical pulps are used in manufacturing newsprints,whereas chemical pulps are used for both cultural varieties andnewsprint.11.TNPL practices combined chemical recovery for bagasse and woodblack liquor.12.Common liquid effluent treatment system is used for the whole mill.


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4 th CESS PROGRAMME "UTILIZATION OF AGRO RESIDUE FIBRES IN INDIAN PAPER INDUSTRY" 9 1 h _ 1 2 ' h MAY '05

13.lt has been reliably learnt that efforts are made by TNPL also to usethe treated effluents for land irrigation.Other mills may be having different practices. They could not be coverhere.It is expected that bagasse and straws will play very important role inIndian paper industry in future also.

38


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4TH CESS PROGRAMME 'UTILIZATION OF AGRO RESIDUE FIBRES IN INDIAN PAPER IINDUSTRY" 9th -rz" MAY '05

RELEVANCE OF NONWOOD FIBRES FOR PAPER MAKING-THE CHALLENGES AHEAD

Dr .S.L.Keswani,Managing Director,Chemprojects Consulting Pvt . Ltd.New Delhi.

About The AuthorDr.S.L.Keswani has been in consulting profession ever since hisreturn from Europe in 1968. He has been one theInittotors ofconsultancy concept in India for pulp and paper industry. Since1974, He heads well established consulting company,Chemprojects ConsultingPvt. Ltd.(formally knowasChemprojectsdesign andEngineeringPvt. Ltd.) whoprovide engineeringservicesfrom concept to commissioningthe pulp,paperandother Chemicaland Process industries, After obtaining Doctor's degree inCellulose Technology from Technical University, Darmstadt(Germany) in 1960, he worked in a well know Swiss consultingcompanyin Berne (Switzerland) primarily in the field of Cellulosebased regenerated fibres and subsequently joined as Head ofResearch and Development of M I s O. Derrioes A.G Dueren(Germany) , a Voith group company. Subsequently, he worked asSr. Process Engineer in a Greek mill, where he got interested inutilization of agro residue for pulpandpapermaking. Fromthere,he returned to India to be of service to Indian Pulpand PaperIndustry.

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4th CESS PROGRAMME "UTILIZATION AGRO RESIDUE FIBRES IN INDIAN PAPER INDUSTRY" gth_12'h MAY '05

RELEVANCE OF NON-WOOD FIBERS FOR PAPER MAKINGTHE CHALLENGES AHEADDR.S.L. KES\VANI1.0 INTRODUCTION

.:. Paper can be made from any cellulose containing fiber resource .. Predominant source is forest based raw material which providessubstantial biomass/hectare. It however, requires long time to grow.

Man made plantations are in vogue worldwide including in India .. In Indian subcontinent, forest based raw-material is scarce andsubstantial quantities of raw-material is not easily available to havesustainable capacity for operating an optimum size of wood based,pulp and paper mill - currently in range of 500 tpd - 1000 tpd. Higher'capacities are coming up in other parts of world where wood basedraw material is available on sustained basis .. Keeping this in view, our country had to look at alternate cellulose

raw materials .. Per capita consumption, which currently is, only 5.5 to 6.0 kg is alsolow that own waste paper generation is not sufficient to meetsubstantia! requirements. Waste paper has also alternate usages .. Paper being demand - driven, it becomes an essential commodity Iproduct for a country of our size to create a sustainable and globallycompetitive industry - alternate raw material sources have to beworked into .. Viewing the above background, it was early seventies that we startedlooking at non-wood fibers, which are mostly annual crops in nature(except bamboo) as a source of cellulose for making paper .. At the initial stage of its development, the slogan became" wealth outof waste" unfortunately, today it is considered as "environmentalburden" and unfriendly and unable to obtain green rating.. Derived from above situation, despite certain negative issues - non-wood fibers have created substantial capacity which is almost 30 -35% of overall paper production.


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.:. Since these raw materials are bulky and seasonal - capacities ofmills is determined on fiber retrievable distance also considering thecompeting demands for alternate uses .. Some non-wood fibers are regional in nature namely;

J uteBagasse Bengal/AssamSugarcane growing areas such as U.P,Maharashtra, Karnataka, Tamil Nadu andAndhra Pradesh.Rice straw Punjab & Haryana, Chattisqarh, Uttaranchal,Andhra Pradesh.Wheat straw - U.P. , Punjab & Haryana, M.P. Gujarat etc.Sabai grass - Foot hills of Himalayas, H.P., Terai etc.

.:. Today, with improved irrigation and agricultural practices, almost allkinds of crops grow in various states thus an additional fiber hasbecome available round the year, resulting into enforceddevelopment and usage of multi-fiber application of paper makingand accordingly technical and technological development..:. Given the above background - role of non-wood fibers wouldcontinue to be very important to meet our requirements of paper andour economy .. It is quite clear that the likes of TNPL would be an exception butmovement from 10 - 30 tpd range can certainly go up to 100 - 200tpd level or may be even more subject to logistics of availability,collection and storage of fiber resource.

2.0 CHALLENGES AHEAD

.:. The industry will have to accept some risks and be innovative .. Substantial development work has been done by research institutessuch as CPPRI and also in-house by industry based on in-housefloor experience of their process"engineers.".:. Consultants and suppliers have also made attempts to developtechnologies and suitable equipments but there are SUbstantial gapsin incorporation by the industry particularly an element of scare andfear of risk factors.

ENTRAL PULP & PAPER RESEARCH INSTITUTE================== 4]


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.:. No development can take place if industry does not show confidencein scientists and engineers .. A few companies have developed installations for solving theirpollution problems though partially but very little has been done ondelignification and bleaching side thus many have preferred optingfor waste paper base.. Our effort is to miniaturize i.e., downsize latest technologies beingapplicable to larger mill to our requirements. for example;

A. Small oxygen delignification for non-wood fiber - 50 tpdB. Small alkali/oxygen stage which is now successfully workingat a couple of mills .

. Similarly, small i.e., smaller than even 100 tpd non-wood fiber pulpingrecovery systems, can be designed economically .. Price of caustic soda would continue to rise as it is directly related toenergy cost. Please understand recovery is indirectly a caustic sodaplant and also source of steam i.e., power - therefore, a useful modelcan be developed .. There will be costs involved; and also risks factors but we do not seeany major pitfall..:. It is encouraging to note that industry is fast expanding and therefore,must take advantage of technological knowledge & confidence inscientists and engineers in solving their problems .. Concluding mindset of the gentlemen who matter and manage thedestiny of their enterprises must change and be flexible .. This is the right time as so far it is good going but one never knows inchanging global competitivity and economic scenario.

4"ENTRAL PULP & PAPER RESEARCH INSTITUTE================== ..


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MORPHOLOGY OFNON WOOD FIBRES

CENTRAL PULP & PAPER RESEARCH INSTITUTE===================


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STRUCTURE OF NON-WOOD RAW MATERIALS

Dr. S . V . SubrahmanyamScientist E - IPCPB DivisionSaharanpur.

About The AuthorDr. Subrahmanyamhasa Masters degree in Botanywith specializationin Wood Science and obtained his Doctoral degree in Botany fromSardar Patel University, Gujarat. .

He joined Hindustan PaperCorporation in 1981in their R&D group inthe Kerala unit andworked in the area of biotechnological applicationinPulp&Paperindustry andevaluation of various fibrous rawmaterialsfor their suitability inPaperindustry.Subsequently in 1990, he joined Central Pulp & Paper ResearchInstitute, Saharanpur as a Scientist. He has worked in the areas ofrefining of woodandnon-woodfibers. He has obtained training in thearea of fiber morphology and quality control from PAPRO, NewZealand. He is currently working inarea of Pulping&Bleaching.

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STRUCTURE OF NON-WOOD RAW MATERIALS

S.V.Subrahmanyam, R.D.Godiyal & A.K.Sharma

Current Global pulp and paper scenario shows that most paper is made fromwood fibers. Of the total pulpand paper production, wood pulp accounts for about90% and the rest is derived from vegetable fibers such as seed hairs, bast fibers,grasses and even animal and mineral fibers. Many specialty paper productiondemands the fibers either than wood. In areas where the wood supply isconstraint, the pulp and paper mills use locally available raw materials such asstraw, bamboo, bagasse, kenaf, jute etc.Indian pulp-and paper scenario shows that it uses 39% of forest based fiber, 31%agro residue based fiber and 30% fiber is derived fromwaste paper. The fibrousraw materials used for the production of different varieties of paper comes fromdifferent sources like wood, bast, leaf of trees, shrubs, and grasses. The Indianpaper industry produces mostly two types of virgin pulps from the fiber sourcesi.e Chemical pulps through either soda process or Kraft process and chemi-mechanical pulps. Each material has distinct morphological characteristics andchemical composition. Morphologicaffeatures- of putp fiber-are the key factorcontrolling the quality of products during papermaking. The fundamentalproperties of any pulp fiber are length, diameter/width, and cell wall thicknesslumen diameter/width. Pulps contain different types of cell types depending onthe source.

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1.0 Classification of fibrous raw materials:The vegetable fiber sources are classified as wood fibers and non-woodfibers. The wood fibers are further classified as softwood fibers those arederived from gymnosperm trees and hardwood fibers, which are derivedIiriiiIt:? ~~ .D.

_ ~ n~ ~ \7rom angiosperm trees.L OW ER PL A NT S

GYMNOSPERMS(SOFTWOOD FIBER) ANG IOSPERMS

MONocon(STRAWS. GRASSES)

The non-wood plant (shrubs and grasses) fibers can be grouped into fourtypes based on the botanical part used inmaking the paper pulp.1. Stalk or culms

fiber:2. Bastfibers:3. Leaf fibers:4. Seed hullfibers:

Cereal straws, Grasses, Reed, Bamboo, Sugarcane(Bagasse).Flax, J ute, Kenaf, HempSisal, AbacaCotton

2.0 Morphology of papermaking cells

The fibrous raw materials have different tissue composition based on thebotanical source. The cells normally found in the paper pulps are fibertracheids (normally present in softwoods) or fibers (found in all otherfibrous rawmaterials), parenchyma, vessels (found in rawmaterials otherthan softwoods and bast fibers) and epidermal cells (mostly found in agroresidues). The composition and structure of these different cellsdetermines the papermaking quality of and acceptability of the fibersource.

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1\I'ir : !'.

~.:;I:i1 \

Fibers and Parenchyma a, b, c - Vessel elements inin non-woods Hardwood pulps;d- fibers in hardwood pulps;e - tracheids in softwood pulps

2.1 Fibers\Fibers are the most useful cellulose material in the pulp. These arenormally long, flexible and form the basic network (web) in the paper.Fibers contribute to the basic strength of the paper. Fiber is longnarrow cell with tapering ends and a central canal known as lumen.The fibers depending upon origin differ significantly. The average fiberlength varies from 3.5 mm in softwoods, O.8-1.2mm in hardwoods, 2-5mm in bast and leafy fibers and1.Omm to 2.5mminstraws,bagasseand bamboo. Weight proportion of fibers in pulp varies from 95% insoftwoods, 65-75% hardwoods and 55-65% in agricultural residues.The papermaking properties of the fiber are attributed to the variousparameters of the fibers such as fiber length, fiber width, fiber wallthickness, and fiber lumen diameter. These primary parametersinfluence the derived parameters like slenderness ratio, coarseness. .and Runkel's ratio of the fibers. The submicroscopic parameters of thefibers such as microfibrillar orientation in various layers of fibers havealso significant influence on the papermaking.

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2.2 Fiber lengthThe papermaking pulps have fiber population with varying lengths. Theheterogeneity of the fiber population influences the papermaking and theknowledge and understanding of the fiber length distribution is highlyessential in predicting the behaviour of a raw material in the papermaking .process. Generally, the fiber length is averaged for a source, which is arelatively easy expression and gives a broad idea for comparison purpose.The average fiber length varies from 3.5 mm in softwoods, 0.8-1.2 mm inhardwoods, 2-5 mm in bast and leafy fibers and 1.0 mm to 2.5mm instraws, bagasse and bamboo. The fibers in a paper web are randomlydistributed and depending on the length of the fiber, the number of fibercrossings increase or decrease. If the number of fiber crossings increasedue to longer fibers, the web is stronger, thereby having higher wet webstrength of the sheet as well as the dry paper strength. The wet webstrength is very critical in high-speed machines.

dimensional view of the light

-~~ ...~._X-I2.3 Fiber widthThaterrns width and diameter ofthe fibers are normally used for allthe practical purposes for thesame dimension. In a two-

microscope, it is not possible to Strength (Tensile, tear and burst) of paper.. . . depends on the number of crossings perdistinguish between Width and 'fiber (Courtesy: Dr.R.P,Kibblewhiteldiameter. The unrefined fibers are normally tubular structures, whichbecome flattened on refining. In the paperweb when the fibers cross overrandomly, the area of fiber cross over (area of bonding) is influenced byfiber width, If the fibers are wide, then the area per cross over increaseswhere the fibers are held together that contributes to the strength of paperweb. For a given fiber length, the fibers with higher fiber width gives higherpaper strength due to increased cross over'are,aper fiber.

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2.3 Fiber lumenThe central cavity in the fiber is known is fiber lumen, which is void.Depending on the extent of void space, the fiber may flatten(collapsibility) to different extents, as the fiber is refined. Higher theextent of collapsibility then higher is the bonded (contact) area. The fiberlumen is different for different species. The fibers in the same sourcehave different fiber lumen due to seasonal variations in the woodformation..For example the late (winter) wood fibers are have narrowerfiber lumen compared to the early (spring) wood fibers. Rind fibers havethicker wall compared to the fibers in vascular bundles as in bagasseand straws.

2.4 Fiber wall thicknessFiberwall is specific to a given fiber source. Depending on the fiber wallthickness the fibers' response to refining varies. Fibers with thin cell

2.6 Parenchyma: It is also called asnonfibrous parenchyma cells arecellulosic. The dimensions of parenchymavary with source raw material. They donotcontribute to the strength of the paperand often create serious drainageproblems affecting the productivityespecially in the agricultural residues.The weight percent of parenchyma(nonfibrous) cells is about 5% insoftwoods, 25-35% in hardwoods and 30 to 45% agriculture residuepulps. The parenchyma is the source of primary fines in virgin chemicalpulp. Reduction of this nonfibrous tissue especially innonwoods is a bigchallenge and wherever it could be effectively reduced, resulted inchemical savings and improved quality of pulp. Raw materialpretreatment methods in agro based paper industry are principallytargeted to reduce the nonfibrous tissue.

Parenchyma cel ofbagasse

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2.7 VesselsThe vessel elements are the single units of the vessels. They are spiralshaped in straws, long, narrow and cylindrical in bagasse and bamboo,short, wide and cylindrical with short tail in the hardwoods. Wherever theyare present, they help in the mobility of pulping liquor (penetration) inlongitudinal direction of chips.

2.8 Epidermal cells: The epidermal cells aresignificantly small cells with serratedmargins. They appear either in groups or assingles. Their presence is noticeable instraws and bagasse. The dimensions of the epidermal cells vary with thetype of straw.

3.0 RICE STRAWOrizasativaRice is a member of the grass family (Gramineae) and belongs to thegenus oryza under tribe oryzeae. The small and medium size paper millsin India make writing and printing paper from rice straw. The randomestimates suggest that 4.0 tons of rice straw is produced per ton of rice.The annual production of rice straw is about 80 million',tones as Cropproduction and about 180 million tones is the residue generation as waste.Rice straw is used for fodder and thatching and therefore less quantity wasavailable for paper industry for paper and board production. The crop toresidue ratio of the Rice straw is about 2.50, out of which, less than 1% isbeing used by paper industry.

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3.1 MorphologyRice Straw is a heterogeneous innature when compared with wood.Straw' consists of stem and leaves.The internodes section is called stalk.It is a hollow tube with an annulusthickness of about 0.5 mm. Typicallya stem has 5-7 nodes. The stalklength increases from base to head.It carries the grain. Stem lengthgreatly varies from species to species, genetic mutation within a species,soil condition and climate. The stem is separated at intervals by nodes. Atthe nodes, a sheath that ends in a leaf blade is formed around the stem.Seed hulls and foreign material is found in straw bales. The agriculturalwaste after extracting the grains is used inpapermaking. It is used in strawboards, cheap grade corrugating, writing and printing paper in admixturewith long fiberdpulp.

,~"':-f+~ lo :>af oreoe!!--+ tjgue

RiceStraw Plant

Surface view of rice straw Sectional view of rice straw

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'~~' .. ,. : . . . . ,~,,,. ' .. -' :.'.', .

.' I

. .

Magnified view of ground tissue Rice straw pulp

3.2 Pulp componentsUnder Scanning Electron Microscope, the stem surface shows spinystructures and silica mapping using X - rays indicate that silica isconcentrated in the surface area.. The fibers appear cylindrical, havingvitreous silica spread all over its surface thereby giving coarse surfaceappearance under low magnification. Under the high magnification, thefibers show characteristic striations on the longitudinal direction. Asseparation of individual epidermal cell is difficult, and epidermal peels areobserved. The rice straw fiber varies from 0.26- to 3.1 in length with anaverage of 1.1 mm and 7-14f,lm in width (average 11.1 urn). The pulpconsists of fibers, parenchyma, vessel epidermal cells and spicules. Thefibers are thick walled and pointed ends. The fibers are small than bambooand bagasse. The parenchyma cells are short or long and rectangular.The vessels are long and narrow. The epidermal cells are conspicuousand abundant with serrated margins often riot separated with epidermalpeel and have distinct papillae on them. Small-oppressed spicules arepresent, difficult to observe.

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4.0

S. Dimensions Unit MPM PunjabNo.A Properties of fiber .1 Fiber Length (Weight 1,07 0,90weigh,ted)(L =0,20 - 4,Omm) mm2 Minimum Fiber Length, inm 0.40 0,263 Maximum Fiber Length, mm 2,7 3,14 Mean Fiber width ( 1 1 = 7 - 45) 1 1m 11,1 13,15 Lumen Diameter 1 1m 2,38 2,86 Cell wall thickness 1 1m' 5,36 4,14B Properties of non-fibrous

tissue7 Length of vessel 1 1m 198.6 227.18 Width of vessel 1 1m 36.6 36.69 Length of Parenchyma 1 1m 83.8 93.61 Width of Parenchyma 1 1m 28.0 26.7\ 1 Arithmetic Fines (L = 0.01 - 0.20 % 64.0 66.6mm)1 Length weighted Fines (L = 0.01 % 25.3 27.7- 0.20 mm)

4.0 WHEAT STRAW

Triticum vulgareThe small and medium size paper mills in India make writing and printingpaper from wheat straw. The random estimates suggest that 3.0 tons ofwheat straw is produced per ton of wheat. The annual production of Wheatstraw is about 60 million tones as Crop production and about 90 milliontones is the residue generation as waste. Wheat straw is used for fodderand thatching and there fore less quantity was available for paper industryfor paper and board production. The crop residue ratio of the wheat straw. is about 1.50. Out of this less than 1% is being used by paper industry.

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4.1 Morphology of wheat straw

Wheat Straw is a heterogenous in nature when compared with wood.Straw consist of stem and leaves. The internodal section is called stalk. It isa hollow tube with an annulus thickness of about 0.5 mm. Typically a stemhas 5-7 nodes. The stalk length increases from base to head. It carries thegrain. Stem length greatly varies from species to species, genetic mutationwithin a species, soil condition and climate. The stem is separated atintervals by nodes. At the nodes, a sheath that ends in a leaf blade isformed around the stem. Seed hulls and foreign material is found in strawbales.

4.2 Tissue compositionLike any botanical tissue, straw consists of cells. A cell has has a multi-corner cross-section. It has a cell wall; inside void portion of cell wall calledlumen. The cell wall consist of 80 to 90 % substance on dry basis. The rest10 to 20 % is deposited within the lumen and consist of silica (5-10 %) andextractives ( 5-15 %).S.No. Botanical part Wt%l. Internodes 46.72. Blades and sheaths 39.93. Nodes 6.94. Glumes 4.15. Grains 0.26. Foreign matter 2.2

I

I

Internode_ _ J NodeWhen viewed under the Scanning Electron Microscope the most of theuseful fibers located at the outer part of the stem i.e. near the skin with alittle area of the fibers being present in the vascular bundle. Theparenchyma cells, which constitute mainly fines, occupy about 75 % of thetotal area. The fibers originating from the out part of internode are thickwalled and those coming from the inner part are called thin walled.However, the bulk of the fibers ( 80%) are from the outer part of stem. The


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cross section of wheat straw stem will differentiate in to differentcategories of cell types, where fiber is 25%, Parenchyma is 75% andvessel proportion is 3%.

4.3 Pulp ComponentsThe wheat straw is normally converted to chemical pulp using sodaprocess in the Indian paper industry. The pulp contains fibers,parenchyma, vessels, and epidermal cells. The fibers are slender andlong and the ends are pointed. The fiber lumen varies from broad tonarrow. The fibers have an average length of 1.22mmand the range isfrom 0.52 to 2.37 mm. The average fiber width is 14.9 microns. Theparenchyma is abundant and barrel-shaped. The epidermal cells vary insize and form, sparsely pitted, have more or less serrated margins andappear ineither groups or singles. The vessel elements are slender andlong.

Dimensionsofwheat strawpulpcomponents:s. Dimensions Unit Wheat StrawNoA Properties of fiber:1. Fiber Length (Weightweighted)(L = 1.150.20 - 4.0mm) mm2. MinimumFiber Length, mm 0.263., MaximumFiber Length, mm 3.844. Mean Fiber width (u=7 - 45) f..lm 15.25. Lumen Diameter f..lm 3.31 I6. Cell wall thickness f..lm 5.95B Properties of non-fibrous tissue7. Length of vessel f..lm 1958. Width of vessel f..lm 27.29. Length of Parenchyma f..lm 19310. Width of Parenchyma f..lm 44.211. Arithmetic Fines (L = 0.01 - 0.20 mm) % 56.912. Lengthweighted Fines (L = 0.01 - 0.20 % 15.9

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5.0 WHEAT STRAW

Paper surface showing various cells



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6.0 BAGASSESaccharum officinarum

Sugar cane (Saccharum officinarum) residue, commonly known asbagasse is one of the prime papermaking fiber source. About 7.2 milliontonnes of bagasse is produced per annum in India. Sugar cane iscultivated inabout4.25 million hectare of agriculture land in India ata yieldrate of 70 ton/hectare. Sugar factories crush about 180 million tons ofsugar cane per year and the season lasts for 150 to 180 days. Majorsugarcane growing states are Utter Pradesh, Maharashtra, Tamilnadu andKarnataka. Bagasse constitutes about 30% of cane processed forproduction of sugar, which is used as a fuel for cogeneration of steamandpower to meet the process requirements. Depending upon the energy

\efficiency, sugar mills also save bagasse, ranging from 4% to 10% oncane. This spare bagasse is used for production of pulp, paper andparticleboard.

Bagasse is highly bulky and its transportation to the paper mills posesserious problems. Hence, the paper plants, which are situated near thesugar mills, are only able to partly utilize bagasse as a raw material forproduction of paper. Bagasse is generated from the renewable agriculturesource its use in paper jndustry reduce the dependency of paper industryon forest based fiber and conservation of forests preventing globalwarming. As per the Development council India (APFSOS/wP/10) the totalbagasse production in 1990 was 7.2 million tons of which 15% wassupplies (1.08) million tones) which is equivalent to 0.18 million tons /yearpaper.

The fibers are obtained from the stem of sugarcane plant after extractingthe juice. The fibers in admixtures with some long fibers are used for themanufacture of all types of cheap grade Cultural and industrial paper. Thefiber varies 0.3 to 4.0 mm in length and width varies from 10 to 40llm The

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wider fibers are thick to thin walled, with straight, pointed tapering endsand relatively more numerous slit like or lenticular pits than in bamboo.Transverse markings similar to those of bamboo are quite common. Thewider fibers are usually shorter and comparatively thin walled notfrequently with blunt, oblique or forked ends. Parenchyma cells are veryabundant, usually appreciably larger than those of bamboo. They are up to900 11min length with- an average of 358 11mand up to 180 11min widthwith an average of 78 11mand serve to distinguish bagasse from bamboo.The parenchyma cells are small to medium sized narrow rectangular andnumerous. Vessels are similar to those of bamboo, ranging from 180 to1600 11mand 30 to 220 11m long and narrow. The epidermal cellssomewhat narrow and rectangular with undulating margins are alwayspresent. Stomata may be rarely present.

BAGASSE

Cross section of bagasse Magnified view of vascular bundle

. J


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Surface view of paper Magnified view of fiber crossings

, ,., '"~'.'."~.. 'K~

' j

Prominent parenchyma cells Enlargedview of fiber, note bright walland fiber lumen

S.No Dimensions I Unit I Bagasse I Bagasse(Punjab) (Chenni)A Properties of fiber:1. Fiber Length (Weight weighted)(L = I mm I 1.24 I 1.520.20- 4.0mm)

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2. Minimum Fiber Length, mm 0.35 0.323. Maximum Fiber Length, mm 3.62 3.94. Mean Fiber width (J .!=7 - 45) J .!m 19.3 21.85. Lumen Diameter J .!m 4.07 6.296. Cell wall thickness J .!m 7.65 7.76B Properties of non-fibrous tissue7. Length of vessel J .!m 287.5 151.68. Width of vessel J .!m 101.4 27:89. Length of Parenchyma J .!m 358.5 327.710. Width of Parenchyma J .!m 78.2 53.211. Arithmetic Fines (L =0.01 - 0.20 mm) % 61.9 58.312. Length weighted Fines (L = 0.01 - % 20.5 17.0

0.20 mm)

,/



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7.0 SARKANDA GRASSSaccharum bengalense .

It is very large erect grass, growing in clumps with following clumps upto 6meter tall found mainly in Punjab, Uttar Pradesh, Bihar, Bangal and orissa,growing well on alluvial sandy banks-of streams not subjected to waterlogging. Culms biennial, pale soild, pithy smooth with an inconspicuousgrowth ring and root zone. Leaves 1-2 meter long and upto 3 cm broad.The fiber obtained from sarkanda grass is quite strong and elastic and notaffected bymoisture.

7.1 MORPHOLOGYThe fiber varies from 0.2- to 3.5 in length (an average of 1.3mm) and 7 to40 Il~ in width (average 15.7 urn). The pulp consists of fibers,parenchyma, and vessel and epidermal cells. The fibers are narrow, long,straight and thick walls and pointed tapering ends and occasionaltransverse markings. The fibers are narrow than bamboo and bagasse.The parenchyma cells are small to medium sized narrow rectangular andnumerous. The vessels are fairly long and narrow. The epidermal cells arenumerous, rectangular and conspicuous with serrated margins.S.No. Dimensions --~-.----.- ---.~- "- ._ - -- Unit SarkandaA Properties of f iber:1. Fiber Length (Weight weighted) (L =0.20 - 1.34.0mm) mm2. MinimumFiber Length, mm 0.503. MaximumFiber Length, mm 4.484. Mean Fiberwidth (Il= 7- 45) Ilm 15.75. Lumen Diameter Ilm 4.246. Cell wall thickness Ilm 5.72B Properties of non-fib rous ti ssue12. Length of vessel Ilm 79.913. Width ofvessel Ilm 30.114. Length of Parenchyma Ilm 14115. Width of Parenchyma Ilm 31.8

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16. Arithmetic Fines (L = 0.01 - 0.20 mm) % 60.S17. Length weighted Fines (L = 0.01 - 0.20 mm) % 16.SB .O SABAI GRASS

Eulaliopsis binataEulaliopsis binata SYN. Ischaemum angustifolium commonly calledSabai, Babui or bhabar, is an important grass species having lot ofcommercial value. It is a tufted perennial grass of family Gramineae. Sabaigrass is grown in large quantities out side forest area. Sabai grass isperennial grass, 2-S ft. high erect, slender culms, shiny and woolly at thebase. Leaves'narrow, linear, 3-4 fit long. The grass flowers during the coldweather and for purposes of paper manufacture, the grass is cut prior to orduring the flowering stage. The yield of the grass varies from 20-7Smdperacre according to locality, rainfall and intensity of management. Sabaigrass when carefully collected free fromweeds and foreign matter, formsan excellent material for the production of printing and medium qualitywriting paper.

B .1 MORPHOLOGY

The fibers are derived from the vascular bundles of leaves. The pulp isesed for the manufacture of all types of cultural and industrial paper. Thefiber varies from 0.4 to 4.4 in length with an average of 1.6 mm and S-1S~m in width (average 13.7 urn). The pulp consists of fibers,parenchyma, and vessel and epidermal cells. The fibers are narrow, long,straight and thick walls and pointed tapering ends and occasionaltransverse markings. The fibers are narrower than those of bamboo andbagasse. The parenchyma cells are small to medium sized narrowrectangular and numerous. The vessels are fairly long and narrow. Theepidermal cells are numerous, rectangular in shape and conspicuous withserrated margins.

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SABAI GRASS PULP

L. "~

~ I ,,;f

Magnified view of pulp fiber' .

Sabai grass pulp

S.No. Dimensions Unit SabaiGrass

A\ Properties of fiber:1. Fiber Length (Weight weighted)(L =0.20- 1.574.0mm) mm2. Minimum Fiber Length, mm 0.353. Maximum Fiber Length, mm 4.44. Mean Fiber width (J .l=7 -45) J .lm 13.55. Lumen Diameter J .lm 1.116 Cell wall thickness J .lm 6.3B Properties of non-fibrous tissue -----.~ --_._- ~ _.- -- -- ------7. Length of vessel J .lm 438. Width of vessel J .lm 309. Length of Parenchyma J .lm 7010. Width of Parenchyma J .lm 1511. Arithmetic Fines (L =0.01 -:-0.20 mm) % 59.712, Length weighted Fines (L =0.01 - 0.20 mm) % 14.0

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9.0 KANS GRASS( Saccharum spontaneum )Kans Grass (Saccharum spontaneum ) popularly known as north Indiancanes is a perennial grass with slender culms green gray, ivory or white,hard, but very pithy. Kans Grass is mainly found in Himalayas of northernIndia and extends up to the equatorial regions of java. Kans Grass is acoarse grass normally not relished by cattle and is generally used as fodderonly in times of scarcity. Kans Grass is often hollow in the center, varying indiameter from5 t015 mm, often rooting atthe node, internodes usually longand nodes always thicker than the internodes. Leaves are long, linear,narrow or very narrow, the leaf module or ratio of breadth to length varyingfrom 1:24 to 1:300 or more in the different forms of the species. Culms-biennial,pale- solid, pithy smooth with an inconspicuous growth ring androot zone. Leaves 1-2 meter long and up to 3 cm broad. This species is ofgreat value for fiber extracted from the upper leaf sheaths of the floweringculms. The leaves are also used for thatching and for purpose of pulpmanufacturing. Keeping its availability and existing utility in view, pulpingand papermaking properties of Kans Grass have been evaluated so that itcan be exploited for pulp and paper manufacture. Kans Pulps suitable forproduction of wrapping, writing printing and greaseproof papers. It is alsoused for hardboard making. The grass can be used in admixture with othergrasses..

~,I


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margins. Epidermal cells' length varies from 57 to 163 urn(average 81 urn) and width from 8 to 16.3 urn (average 13.5 urn).S.No. Dimensions Unit KansGrass

A Properties of fiber:1. Fiber Length (Weight weighted) (L =0.20 - 5.0mm) mm 1.42. Minimum Fiber Length, mm 0.433. Maximum Fiber Length, mm 3.574. Mean Fiber width (J .!=7 - 35) J .!m 15.45. Lumen Diameter J .!m 1.146. Cell wall thickness J .!m 6.38B Properties of non-fibrous tissue7. B Length of vessel J .!m 489.08. Width of vessel J .!m 38.09. Length of Parenchyma J .!m 91.110. Width of Parenchyma J .!m 35.011. Arithmetic Fines (L =0.01 - 0.20 mm) % 55.7112. Length weighted Fines (L =0.01 - 0.20 mm) % 13.59

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4thCESS PROGRAMME "UTILIZATION OF AGRO RESIDUE FIBRES IN INDIAN PAPER INDUSTRY: 9th_12th MAY '05

10.0 BAMBOO

Bamboo is a perennial, giant, woody grass belonging to the tribeBambuseae of the well-known family of Gramineae in group angiospermsand the order monocotyledon. The grass family Poaceae (or Gramineae)can be divided into one small subfamily, Centothecoideae, and five largesubfamilies, Arundinoideae, Pooideae, Chloridodeae, Panicoideae, andBambusoideae. In distinction to its name, bamboos are classified underthe sub-family Bambusoideae. About 1200-1500 species of 60-70 generaof bamboo are known to exist in the world. More than half of these speciesgrow in Asia, most of them within J apan and Indo-Burmese region, whichis considered their area of origin. In India out of 136 species identified, 30_ 40 species are extensively available for economic exploitation. Someexamples of bamboo genera are Bambusa, Chusquea, Dendroealamus,Phyllostaehys, Gigantoehloa and Sehizostaehyum.

10.1 MORPHOLOGY AND GROWTHMany species of bamboo exist but the morphology of the cell tissue isalmost similar. Bamboo species flower at regular interval but variousspecies have different flowering periods. Some flower sporadically andsome gregariously. The life cycle of different species various from 30 to 60years. After periodic flowering, seeding and death of bamboo, there will bean interruption of supplies for a period of 8 to 12 years. It is alwaysadvisable to have a bamboo crop of different species flowering at differentperiods. The flowering cycle (in years) in bamboo varies with species viz.Bambusa bamboo, (30-40); Arundinaeea falcate, (28-30); Oehlandratravaneoriea , (28-30); Bambusa polymurpha, (55-60); Dendraealmusstrietus, (30-40); Meloeanna bambusoides, (45); Bambusa arundinaeea,(32-34); Bambusa tulda, (40) represents the general structure of bamboo.Rhizomes and culms are the two important portion of Bamboo. Therhizome is the underground part of the stemand is mostly sympodial or, toa much lesser degree, monopodial. The upper part of stem is known as

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4th CESS PROGRAMME "UTILIZATION OF AGRO RESIDUE FIBRES IN INDIAN PAPER INDUSTRY: 9th_12'h MAY '05

culms and is used for papermaking. Culm portion of the bamboo treecontains most of the woody material. Most of bamboo culms are cylindricaland hollow, with diameters ranging from 0.25 inch to 12 inches, and heightranging from 1 foot to 120 feet. It is without any bark and has a hardsmooth outer skin due to the presence of silica.Species Average Height Internodes, Diameter,(m) (cm) (cm)Bambusa 26-30 30-40 15-18arundinaceaDendracalamus 6-16 30-40 2.5-7.5strictusOchlandra species 2.;.6 60-120 2.5-5.0Bamboo is a fast growing species and a high yield renewable resource.Bamboo growth depends on species, but generally, all bamboo maturesquickly. Bamboo may have 40 to 50 stems in one clump, which adds 10 to20 culms yearly. Bamboo can reach its maximum height in 4.to 6 monthswith a daily increment of 15 to18 cm (5 to 7 inches). Culmstake 2 to 6 years to mature,which depends on thespecies. Bamboo mature inabout 3 to 5 years and with agood management of thebamboo resource, the cuttingcycle is normally 3 years as its Thick and thin wall bamboo in stackgrowth is more rapid than anyother plant on the plant. Some bamboo species have been observed tosurge skyward as fast as 48 inches in one-day. The fast growthcharacteristic of bamboo is an important incentive for its utilization. Thecurrent Bamboo consumption rate by pulp & paper industry in India is inthe range of 0.8 to 1.0million A.D. tons.

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4th CESS PROGRAMME "UTILIZATION OF AGRO RESIDUE FIBRES IN INDIAN PAPER INDUSTRY: 9th _12'h MAY '05

General morphology of bamboo remains the same for all species. Rhizomesand culms are the two important botanical parts in bamboo structure, wherethe former is underground part of the stem and later is the surface part of thestem. The culms those are apparent stem parts have the papermakingpotential. The bamboo culms are cylindrical and hollow, with diametersranging from 1 cm to 30 cm having height ranging from 0.5 meter to 40meters. The culms have no bark like the other wood trees, which is anadvantage in processing. Bamboo culms can reach its maximum height in 4 to6 months, but require 2 to 6 years to mature. Tropical climatic conditionsinfluence the extraction of bamboo from forests and its transportation to millsite. As the felling stops for 4 to 5 months, proper storage and preservation ofbamboo are important for smooth running of the mills. The extraction ofimmature culms results in financial losses and the pulp and papermakingcharacteristics are adversely affected.

Bamboo culms are extracted from the forests, cut to about two meter lengthpieces, bundled and stacked, which in turn transported to the interim depots.The freshly extracted bamboos have moisture content ranging from 75% to50%. From these interim depots, the material is moved by road or rail route tothe mill sites. The prolonged storage at the extraction sites leads to seriousdamage due biological infestations and microbial attack and adversely affectsthe quality of pulp. It is suggested that there should be concrete paved yardsin the mills and the bamboo bundles should be stacked in criss-cross fashionto improve ventilation and drainage of rainwater. The inventory of bamboostorage in a mill should be decided keeping in view the location, infrastructureand production capacities, such that it should not interrupt the sustainedsupply of bamboo to the mill.

10.2 MORPHOLOGYOF BAMBOOCULMS:

The bamboo culms are divided in to segments by nodes. The segmentsbetween tow nodes are known as nodes. Outermost cellular layer ofbamboo cum is epidermis upon which a waxy layer exists, which gives the

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smoothness to surface. The fibers appear in layers below the epidermisfollowed by ground tissue. The vascular bundles, which also containfibers, are distributed in the ground tissue, which are more closely packedtowards the periphery of the stem and scattered towards the inner side inthe ground tissue, which causes the differential density of in concentriclayers of bamboo. This differential density of bamboo poses biggestchallenge to the chip quality management in the chipper house. The bulkdensity of bamboo chips range between 180 to 250 kg/m3. The bulkdensity of bamboo chips can be as low as 120 kg/m3 in case of immaturebamboo. The bamboo fibers are slender and long. The average lengths ofthe fibers vary between 1.8 mm to 2.5 mm depending upon the species.Similarly, the fiber width varies between 8 urn to 12 urn

Vascular bundle in ground tissue

Bamboo chips Bamboo pulp f ibersBamboo pulp is capable of fine writing and printing paper standards,offering similar strength, brightness and printability of comparable woodpulp-based papers. Bamboo has it's own papermaking potential, whichcan hardly be substituted by other raw materials. Bamboo has its~ 1 ~ r m ~ p ~ . ) % 68~\ ~ CENTRAL P U LP & P AP ER RES EARCH INS T ITUTE====================' I : ~ . : ~:t"CH'tI.''\\


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maximum resistance to mechanical forces in transverse direction and thesmooth surface of the culms; differential density of the culms in concentriclayers makes it difficult to achieve clean chipping process. These factors,when the bamboo is not seasoned properly causes more slivers (largechips) and pin chips (botanically vascular strands) and dust (parenchymacells). This non-uniformity in the chip quality is not a serious problem inbatch digestion, but poses serious operational problems when processedin continues digesters due to chocking of the digester screens leading tointerruptions in pulping liquor circulation. Nodes in the chips are difficult topulp as the grain (fibers) and other tissues are intertwined in them causingtightly packing and hinder the pulping liquor penetration. Bamboo hascapillary structures (vessels) running vertically throughout the length inregular distances in the internodes help in pulping liquor movement. Thesecapillaries have air, if the chips are dry and expulsion of air necessary priorpulping process. Steaming of chips would help in expulsion of theentrapped air in the capillaries.

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agro residue_paper industry

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