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15/01/2010 PREPARED BY : M. MERIH AYDIN BARIS TOR RANA OKUR GOZDE YILMAZ MODERN CARDBOARD CORPORATION Slide 2 Modern Cardboard Corporation Sector: Corrugated Cardboard Year of Establishment :1981 Production Capacity : 700.000 tons/year Closed Area :130.000 m Open Area :530.000 m Number of Employees :440 Slide 3 Modern Cardboard Corporation Manufacturing technology, Automation system the most advanced technologies in the paper industry. Major paper manufacturer in Europe. (700.000tons/year) Slide 4 Modern Cardboard Corporation Paper exports leader of Turkey. Raw material: 100% recyclable paper (saves 4.5 million grown trees in a year. ) Process water supplied from reuse of wastewater (60 %) and the rest from the wells near the factory. Slide 5 Modern Cardboard Corporation due to these characteristics and its purification system which is worth 15 million usd, the facility is strictly environment friendly. Slide 6 PRODUCTION PROCESS Slide 7 Raw Materials used: Water Waste Cardboard Products: Kraft Paper Cardboard Corrugated Cardboard Slide 8 PRODUCTION PROCESS Additives: Bleaching agents Starch Calcium Carbonate Sodium Hydroxide Sulfur Compounds Slide 9 PRODUCTION PROCESS Pulp Preparation Shredding and mixing with water Krafting Lignin and wood fibres separation Corrugating Corrugated mid-layer preparation and cardboard production Quality Control Pressure, water, elongation resistance Slide 10 Slide 11 PRODUCTION PROCESS Slide 12 Slide 13 WASTEWATER TREATMENT PLANT Slide 14 Modern Cardboard Corporation Units of wastewater treatment plant Primary Sedimentation Equalization Tank Anaerobic Reactor Aerobic Reactor Secondary Clarifier Sludge Dewatering Slide 15 Modern Cardboard Corporation Primary Sedimentation : to remove & reuse SS (fbers) and important in terms of decreasing organic load and recycling of paper fiber Primary Sedimentation Recovered Fiber Pulp Production Initial WW Slide 16 Modern Cardboard Corporation Aneorebic Treatment & Aerobic treatments are respectively used because ; Wastewater produced in paper industry has signifcant organic loadings Biological treatment is the efficient and cheapest treatment technology for paper industry. Slide 17 Modern Cardboard Corporation Wastewater produced in industry ranges from 4000 to 6000 mg COD /L Activated sludge process and mechanical aerated tanks are used. High strength wastewater streams is sent to anaerobic system before aerobic system to decrease aeration cost and operational cost. Slide 18 Up flow Anaerobic Sludge Reactor Feeding water coming from bottom part of tank rises and passes through granular bacterial bed. Seperation of sludge and biogas collection at upflow of anaerobic reactor. Biogas collected Wet scrubber washed biogas used in the boiler to produce heat. Ths is method is environmental friendly &cost effective technology Slide 19 Up flow Anaerobic Sludge Reactor Influent waste stream Biogas BOILERS Storage Slide 20 Modern Cardboard Corporation Sedimentation is the final step of conventional wastewater treatment system. Reuse of water with membrane system is actively used in company. Using nanofiltration filtration system % 60 of effluent stream is reused. By using membrane system; Dissolved solids and refactory organics removed to prevent interferences with production process & to meet water discharge criteria. Slide 21 Modern Cardboard Corporation Final step is of treatment is dewatering unit ; Belt filters with pre-thickening with belt gravity thickeners are used for the dewatering of the sludge. After dewatering lime addition, 30-35 % solids containing sludge production. Sludge cake is transferred to municipality landfill for ultimate disposal. Slide 22 Slide 23 WASTE CHARACTERIZATION Slide 24 SOLID WASTES sludge cake, municipal solid wastes,MUNICIPAL LANDFILL hazardous wastes. Hazardous waste is composed of ink boxes, glue boxes, starches. They are sent to incineration once a year. Slide 25 WASTEWATER Domestic wastewater Process wastewater (starch, calcium carbonate, ventonit, COD, SS) Domestic wastewater is collected in a septic tank and regularly sent to municipal wastewater treatment plant by sewage truck. Slide 26 RECOMMENDATIONS Odor problem (TRS) in dewatering building. Placing an activated carbon filter or biofilters could be a solution for that problem. Odorous air can be fed directly or by the perforated pipes to the filter, Nutrients and adequate water must be supplied to biofilters to produce the bacterial growth in the filter media to treat odor. Filter materials: compost of bark, compost, wood mix, heather, peat and coconut fibres. Slide 27 Fields of application for biofilters: Deodorization (for example: municipal waste water treatment plants, composting, food industry, paper industry etc.) Exhaust air purification (for example: metal industry, foundry industry, textile industry, chemical industry etc.) Slide 28 RECOMMENDATIONS To increase the efficiency of dewatering a DAF unit could be installed as a sludge thickener. For a fiber containing gelatinous activated sludge DAF thickening is feasible and useful before sludge dewatering. Sludge drying may be achieved by using waste steam from flues. Slide 29 REFERENCES http://www.erenholding.com.tr/sectors/paper/modern_k arton http://www.training.gpa.unep.org/images/jpg/upflow_ana erobic_reactor_sm.jpg Biological Wastewater Treatment: Principles, Modelling and Design, Mogens Henze,Mark C. M. van Loosdrecht,George A. Ekama, 2008 Wastewater Engineering: Treatment and Reuse, Metcalf and Eddy, 4 th Edition, page: 687, table 8.7. Wastewater Engineering: Treatment and Reuse, Metcalf and Eddy, 4 th Edition, page: 1565 Slide 30 THANK YOU