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15/01/2010PREPARED BY :M. MERIH AYDINBARIS TORRANA OKURGOZDE YILMAZMODERN CARDBOARD CORPORATION

Modern Cardboard Corporation Sector: Corrugated Cardboard Year of Establishment:1981Production Capacity: 700.000 tons/yearClosed Area:130.000 mOpen Area:530.000 mNumber of Employees:440Modern Cardboard CorporationManufacturing technology,

Automation system the most advanced technologies in the paper industry.

Major paper manufacturer in Europe. (700.000tons/year)Modern Cardboard CorporationPaper 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.

Modern Cardboard Corporationdue to these characteristics and its purification system which is worth 15 million usd, the facility is strictly environment friendly.

PRODUCTION PROCESS

PRODUCTION PROCESSRaw Materials used:WaterWaste Cardboard

Products:Kraft PaperCardboardCorrugated CardboardPRODUCTION PROCESSAdditives:Bleaching agentsStarchCalcium CarbonateSodium HydroxideSulfur Compounds

PRODUCTION PROCESSPulp Preparation Shredding and mixing with waterKraftingLignin and wood fibres separationCorrugatingCorrugated mid-layer preparation and cardboard productionQuality ControlPressure, water, elongation resistance

PRODUCTION PROCESS

PRODUCTION PROCESS

WASTEWATER TREATMENT PLANT

Modern Cardboard CorporationUnits of wastewater treatment plant

Primary SedimentationEqualization TankAnaerobic ReactorAerobic ReactorSecondary ClarifierSludge Dewatering

14Modern Cardboard CorporationPrimary Sedimentation : to remove & reuse SS (fbers) and important in terms of decreasing organic load and recycling of paper fiber

Primary SedimentationRecovered Fiber Pulp ProductionInitial WW15Modern Cardboard CorporationAneorebic Treatment & Aerobic treatments are respectively used because ;

Wastewater produced in paper industry has signifcant organic loadingsBiological treatment is the efficient and cheapest treatment technology for paper industry.16Modern Cardboard CorporationWastewater 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.17Up flow Anaerobic Sludge ReactorFeeding water coming from bottom part of tank rises and passes through granular bacterial bed.

Seperation of sludge and biogas collection at upflow of anaerobicreactor.

Biogas collected Wet scrubber washed biogas used in the boiler to produce heat.

Ths is method is environmental friendly &cost effective technology

18Up flow Anaerobic Sludge Reactor

Influent waste streamBiogas BOILERSStorage19Modern Cardboard CorporationSedimentation 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. 20Modern Cardboard CorporationFinal 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.

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WASTE CHARACTERIZATION

SOLID WASTESsludge cake, municipal solid wastes,MUNICIPAL LANDFILLhazardous wastes.

Hazardous waste is composed of ink boxes, glue boxes, starches. They are sent to incineration once a year.

According to landfill disposal standards, sludge cake from dewatering is suitable for municipal landfill. So 24WASTEWATERDomestic 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.

RECOMMENDATIONSOdor 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.

There is an odor control problem which is cause by TRS (Total Reduced Sulfure) compounds in dewatering building. It is thought that placing an activated carbon filter or biofilter could be a solution for that problem. 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.

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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.)

RECOMMENDATIONSTo 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.

REFERENCEShttp://www.erenholding.com.tr/sectors/paper/modern_karton http://www.training.gpa.unep.org/images/jpg/upflow_anaerobic_reactor_sm.jpgBiological Wastewater Treatment: Principles, Modelling and Design, Mogens Henze,Mark C. M. van Loosdrecht,George A. Ekama, 2008Wastewater Engineering: Treatment and Reuse, Metcalf and Eddy, 4th Edition, page: 687, table 8.7.Wastewater Engineering: Treatment and Reuse, Metcalf and Eddy, 4th Edition, page: 1565

THANK YOU

Pulping

Krafting

Storage & Shipping of Kraft Rolls

Corrugating

Quality Control

Storage & Shipping of Cardboard

Shredding

Kraft Paper Rolls

Cardboard

Process Water

Pulp

Kraft Paper

Steam

Waste Steam

Wastewater

Cardboard

Treatment Plant

Plant Air Conditioning

Hot Water From HE

Process Water

Sludge Cake

Treated WW Discharge

Process Water

Waste cardborad

Steam

Waste Steam

Treatment Plant

Boiler

Flue Gas

Primary Sedimentation

Equalization Tank

Heat Exchanger

Anaerobic Reactor

Aerobic Reactor

Secondary Clarifier

Sludge Dewatering

Sludge Cake

Sludge Conditioning

Cake Shipment

Primary Sludge

Wastewater

Wastewater Discharge

Pumping

Dissolved Air Floatation

Membrane Filtation

Water Softening

Clarified WW

Process Water for Kraft Process

Boiler

Steam

Waste Steam

Wastewater

Wastewater

Wastewater

Hot Water for AC

Blow-off Water

Treatment Plant

Flue Gas