Interview with Mr. J P. Narain, CEO of Fibertec and Business Transformation Partner
Fibertec stands as a prominent EPC and Consultancy Company, featuring a dedicated team of design engineers, planners, process specialists, and financial analysts.
Paper Desk : How much water is typically used in your paper mill’s production process, and how do you measure and monitor water usage across different stages of production?
J.P.Narain : Water usage in paper mills varies depending on the type of paper produced and the process used. Typically, it can range from 1.5 to 30 cubic meters of water per ton of paper produced. Mills monitor water usage through metered systems at various stages of production: in the pulping, papermaking, and other processes.
Water meters and flow sensors are installed to track the input, usage, and discharge of water, and this data is often collected in real-time using automated monitoring systems. Now water consumption is paid and these monitoring systems are essential for regulatory as well commercial purpose also.
PD : What technologies and strategies has your mill implemented to reduce water consumption effectively?
JPN : To reduce water consumption, paper mills have implemented several strategies, such as:
- Closed-loop water systems: This involves recycling water within the plant, treating water and recycling to minimizing freshwater intake.
- Water-efficient equipment: Modern papermaking machines, high-efficiency washers, and dryers reduce the volume of water needed.
- Process optimization: Advanced control systems are used to optimize water usage by monitoring and adjusting parameters in real-time.
“Drawing from extensive operational and project knowledge spanning diverse interconnected sectors, we offer holistic EPC and consultancy services to our clients”
PD : How does your mill approach water recycling, and what percentage of water is generally reused within your production process?
JPN : Our paper mills recycle a significant portion of their water. in our Moradabad plant we recycle 100% water and having zero liquid discharge, in Muzaffarnagar we recycle up to 66% of water used in the production process can be treated as rreused water . Closed-loop water systems allow for the reuse of water in various stages, such as washing and cooling, which reduces the need for fresh water. Water is filtered, treated, and reintroduced into the process, making it possible to minimize environmental impact.,
PD : What types of final water treatment processes does your mill use, and how do you ensure compliance with environmental standards?
JPN : Final water treatment processes in paper mills include:
- In our mills we treat water with activated sludge systems: These treat water by using air and bacteria to break down pollutants. Mills ensure compliance by regularly testing water quality, implementing environmental monitoring programs, and adhering to local and national environmental standards.
- Biological treatment: Using bacteria and other organisms to break down organic material in wastewater.
- Chemical treatment: Adding flocculants to help remove solid through clarification process.
- Membrane filtration: Using technologies like ultra filteration
The Company prioritizes to ensure compliance with all the standards.
PD : How does your team maintain water quality throughout the production process, and what challenges do you face in doing so?
JPN : Maintaining water quality involves rigorous monitoring, filtration, and regular cleaning of water-recycling systems. Challenges include:
- Contaminant buildup: Fine fibers, chemicals, and organic matter can accumulate and affect water quality.
- Temperature control: Water temperature can influence the effectiveness of treatment processes.
- Chemical residues: Residual chemicals from the papermaking process need to be carefully controlled to avoid contaminating recycled water. To address these issues, mills may use advanced water filtration and conditioning systems and ensure continuous real-time water quality monitoring.
PD : What are the primary sources of water pollution in your mill’s papermaking process, and what measures are in place to mitigate these effects?
JPN : The primary sources of water pollution in our mill include:
- Pulping chemicals: Sodium hydroxide gums, starch and other fiberous material can end up in wastewater.
- Suspended solids: Tiny fibres and fillers from the papermaking process.
- Organic material: organic matter like cellulose fibres ., To mitigate these, mills:
- Implement water treatment systems that target both chemical and organic pollutants.
- Adopt closed-loop systems to minimize the release of solids into the environment.
- Use eco-friendly chemicals wherever possible.
PD : How do fluctuations in water availability, such as during droughts, impact your production process, and what contingency plans does your mill have in place?
JPN : Water availability can significantly impact production, especially in our regions this issue is not there . During such times, mills may take following actions
- Limit production: Reduce the volume of water-intensive processes.
- Increase water recycling: Maximize the reuse of water within the system.
- Alternative water sources: Use groundwater or reclaimed water if available. Contingency plans include maintaining a buffer of stored water and working with local authorities to ensure sustainable water use.
PD : How does your mill handle wastewater, and what methods do you use to minimize its impact on local ecosystems?
JPN : Wastewater is typically treated on-site before being discharged into the environment. Methods to minimize impact include:
- Effluent treatment plants (ETPs): These systems help treat wastewater through chemical, biological, and physical processes to remove pollutants.
- Wastewater reuse: we use recycle treated water for non-production uses like cooling and irrigation.
- Sludge management: Solid waste from treatment is managed responsibly, often by converting it into compost or using it as biomass fuel.
PD : What role does regulation play in water management at your mill, and how do you adapt to changing regulations on water usage and discharge?
JPN : Regulations play a crucial role in water management by setting limits on water usage, quality, and effluent discharge. Paper mills adhere to local, and national regulations, such as norms given by state pollution control board and central pollution control board and update their processes in response to regulatory changes. Compliance includes regular reporting, implementing updated technologies, and investing in continuous water quality testing. Adaptation to changing regulations may involve upgrading treatment plants, modifying production processes, or reducing water consumption.
PD : Could you share any recent innovations your mill has implemented in water management, and how have they affected sustainability and operational costs?
JPN : Recent innovations adopted by our mill:
- Advanced technologies: Innovations like zero liquid discharge which deploy complete treatment of water and using reverse osmosis process help recycle maximum water and improve quality.
- Smart water management systems: IoT-based systems for real-time monitoring and predictive maintenance. These innovations can lead to significant reductions in water consumption, lowered operational costs, and improved sustainability by reducing freshwater dependence and minimizing wastewater discharge.
“Paper mills adhere to local, and national regulations, such as norms given by state pollution control board and central pollution control board and update their processes in response to regulatory changes”
