Presentation in PT Toba Pulp Lestari,Tbk

By :By :Nurmay Siska R Siallagan/ 10022336Nurmay Siska R Siallagan/ 10022336

GT Environmental DepartmentGT Environmental Department

Dr. Raghunath Varanasi & Jekson Dr. Raghunath Varanasi & Jekson Sinurat, STSinurat, ST

Join Date at May 7 2010Join Date at May 7 2010

15 Oktober 2010 15 Oktober 2010

Table of Content :Table of Content :

1. Overview Wood Preparation2. Overview Fiber Line3. Overview Recovery Boiler, Evaporator, Multi Fuel

Boiler and Water Treatment Plant4. Analysis Water (Waste Water, River Water/ Bore

well) and Emission5. Regulation and License6. Solid Waste Management7. Symbol and Label B3 (Material and Waste)

Apr 18, 2023 Nurmay Siska Rosilawati Siallagan 2

Introduction


Process Area

1. Wood Preparation Plant

2. Fiber Line Plant

3. Chemical Plant

4. Recaustisizing and Lime Kiln Plant

5. Coal Gasifier Plant and Energy Plant

6. Effluent Treatment Plant

Fiber Line Plant

Digester

Washing and Screening

Bleaching

Pulp Machine

Technical Department

Quality Control/ Assurance (QC/QA)

Environment

Quality and Environment Management System (QEMS)

Energy

Evaporator

Recovery Boiler

Multi Fuel Boiler

Water Treatment Plant

Wood PreparationWood Preparation


DebarkingDrum

DebarkingDrum

WashingStation

WashingStation ChipperChipper ScreeningScreening Chip PileChip Pile

To Digester

Wood yardWood yard

Barks to Pallman Chipper as Fuel to MFB

Oversize Chips

Source waste that Impact to environmental such:1. Waste water from washing and Drain Chip Pile.2.Solid waste from Debarking drum (barks),Chipper(dust) and Screening (undersize chips).

Digester PlantDigester Plant


DKP Process DKP Process ::

BKP Process BKP Process ::

The main chemical reactions in the cooking process can be The main chemical reactions in the cooking process can be described as :described as :(NaOH,Na(NaOH,Na22S) + Chips (wood) S) + Chips (wood) → → Na-org + S-org + NaHSNa-org + S-org + NaHS

Chip FillingChip Filling

Prehydrolisisramp

Prehydrolisisramp

Prehydrolisiscook

Prehydrolisiscook

Prehydrolisisrelief

Prehydrolisisrelief

LiquidFillingLiquidFilling

KraftRampKraftRamp

KraftcookKraftcookBlowingBlowing

Chip FillingChip Filling

Liquid FillingLiquid Filling

KraftRampKraftRamp

Kraftcooking

Kraftcooking BlowingBlowing

PulpStock

Pulp Stock

30 min 70 min 90 min 20 min 30 min 40 min

70 min20 min

30 min 30 min 70 min 90 min 20 min

Cooking process for DKP = 370 minCooking process for BKP = 240 min

Block diagram process digester Block diagram process digester plantplant


Source of waste from digester :Source of waste from digester :- Liquid from over flow accumulator tank.- Liquid from over flow accumulator tank.- Gas :NCG from air evacuation, relief, foam tank and WL - Gas :NCG from air evacuation, relief, foam tank and WL tank, vapor tank, vapor blow tank.blow tank.

Contaminated condensateTo stripper condensate

CondensateTo Effluent

NCG toincinerator

Liquor HeaterLiquor Heater

Digester Digester

AccumulatorAccumulator

Blow TankBlow Tank

MPSteam

WL

WL

Chips

LPSteam

Pulp DigestingBrown Stock Pulp to BSW

Condensate toBFW

Washing and ScreeningWashing and Screening


Brown StockPulp From Digester

Source of waste from washing :Source of waste from washing :DNCG from washer hood 1,2,3,4.DNCG from washer hood 1,2,3,4.Solid from screening system as Shive.Solid from screening system as Shive.

Combine condensateHot Water

Radi ScreenRadi

ScreenWasher

#1Washer

#1Washer

#2Washer

#2Washer

#3Washer

#3Wash StockWash Stock

Washer #4

Washer #4

High Density Storage

High Density Storage

ScreeningSystem

ScreeningSystem

FiltrateTank #4FiltrateTank #4




Screw Press

Screw Press

KnotsRe-cookedTo Digester

WBL toEvaporator

Unbleached PulpTo Bleaching Plant

Fiber Reject asSolid fuel to boiler

DNCG toIncinerator

Bleaching PlantBleaching Plant


Unbleached PulpFrom BSW

Bleached PulpTo Pulp Machine

Bleached HD TowerBleached HD Tower

Do Stage andWasher

Do Stage andWasher

EOP Stage and Washer EOP Stage

and Washer D1 Stage and

Washer D1 Stage and

Washer D2 Stage and

Washer D2 Stage and

Washer

Filtrate Tank #DoFiltrate

Tank #DoFiltrate

Tank #EOPFiltrate

Tank #EOPFiltrate

Tank #D1Filtrate

Tank #D1Filtrate

Tank #D2Filtrate

Tank #D2

ClO2H2O2O2NaOH

ClO2 ClO2

ShowerWasher

ShowerWasher

ShowerWasher

Waste Water toAlkali Sewer

Waste Water toAcid Sewer

NCG toFlue gas

NCG toScrubbing Bleach

Plant

Source waste from bleaching plant are:- Acid liquid from filtrate tank Do, D1 and D2.- Alkali liquid from filtrate tank EOP.- Gas from washer hoods, Filtrate tank and Tower.


SO2

Scrubbing Bleach Plant System

Scrubber

EO Filtrasi

Gas from Washer hoods and Tower

Gas from Filtrate Tank

Stack

to Sewer

Flue gas

Pulp MachinePulp Machine


Source waste from pulp machine is over flow white water Source waste from pulp machine is over flow white water tank and reject pulp sewer.tank and reject pulp sewer.

Bleach pulpFrom Bleaching

StorageChest

StorageChest

PressureScreen

PressureScreen RadicloneRadiclone Double

ThickenerDouble

ThickenerStock ChestStock Chest

Machine Chest

Machine Chest

Head BoxHead BoxFourdrinierFourdrinierPress PartPress PartFlaktDryerFlaktDryer

Cutter &Layboy

Cutter &Layboy

Bailing line

Bailing line

Vacuum Vacuum White WaterSteam Condensate

To BFWDry Pulp toWare House

Steam

Reject Pulp toVibrating Screen

Reject PulpTo Sewer

EvaporatorEvaporator


WBL fromBSW

WBL StorageTank

WBL StorageTank

Effect VEffect V Effect IVEffect IV Effect IIIEffect III Effect II ABEffect II AB

SurfaceCondenser

SurfaceCondenser

StripperColumnStripperColumn

ContaminatedCondensate

Tank

ContaminatedCondensate

Tank

StripperCondenser

StripperCondenser

IBLTankIBL

TankCombineCondensate

Tank

CombineCondensate

Tank

Effect I A,B,C,D

Concentrator

HBLTankHBLTank

Mill Water

CNCG to Incinerator

Warm Water toFiber Line &

Return to WTP

CombineCondensate to

Process

LP Steam

Pure CondensateBFW

HBL to Recovery

Foul CondensateFrom Digester &

Evaporator

Stripper CondensateTo Effluent

LP SteamCNCG toIncinerator

Line steam and gasLine liquidSource of waste from Evaporator is CNCG Source of waste from Evaporator is CNCG

and condensate from stripper column.and condensate from stripper column.

Recovery BoilerRecovery Boiler


Dissolve Tank

Heavy Black LiquorFrom Evaporator

Make upSalt cake

Steam

Smelt

Green LiquorTo Causticization

Weak Wash From Recausticizing

FurnaceChamber

Primary Air

Secondary Air

Tertiary Air

ESP

Dust Recycle

Flue Gas

Flue Gas

Multi Fuel BoilerMulti Fuel Boiler


Flue Gas

Steam Drum ECONOMIZER

HP Steam to TurbineGenerator

Boiler FeedWater

Sand

SH1

SH2

SH3

BoilerBlowdown

Air

Solid Fuel(barks, peat,

palm shell, wood chip)

ESP #2

ESP #1

Ash Silo

Ash Dump

Stack

Fly Ash

Fly Ash

Source of waste from multi fuel boiler is flue gas and Source of waste from multi fuel boiler is flue gas and ash.ash.

IncineratorIncineratorComponent NCG are :1. H2S (Hydrogen Sulfite).

2. CH3SH (Methyl Mercaptan).

3. (CH3)2S (Dimethyl Sulfide).

4. (CH3)2S (DiMethyl Disulfide).Process in incinerator is oxidation process from gases which sulfur contents to be gases which SO2, H2O, CO2 contents.This incinerator operated at temperature 850 – 1050 0C. And reaction is :H2S + ½ O2 → H2O + SO2

CH3S + O2 → H2O + SO2 + CO2

SO2 from the reaction will be absorption in SO2 scrubber with use caustic solution. The reaction is :SO2 + 2NaOH → Na2SO3 + H2O.


Water Treatment PlantWater Treatment Plant


AsahanRiver

F

Gravity Filter

Filter WaterReservoir

Clarifier WaterReservoir

Mill Process Water

RapidMixing Slow

Mixing

SettlingBasin

F

F

CoolingTower

Cooling Water Recycling

Waste WaterTo Effluent

Cooling Water Drain toEffluent

Sludge to river

Regulation And LicenseRegulation And License

A. Regulation.- UU RI No. 32 Tahun 2009 “Perlindungan dan

Pengelolaan Lingkungan Hidup”.- UU RI No. 18 Tahun 2008 “Pengelolaan Sampah”.- PP RI No.18 Tahun 1999 jo 85 Tahun 1999

“Pengelolaan Limbah Bahan Berbahaya dan Beracun”.

- PP RI No. 41 Tahun 1999 “Pengendalian Pencemaran Udara”.

- PP RI No. 82 Tahun 2001 “Pengelolaan Kualitas Air dan Pengendalian Pencemaran Air”.

- PP RI No. 85 Tahun 1999 “Perubahan Atas PP No.18/1999 Tentang Pengelolaan Limbah Bahan Berbahaya dan Beracun.


Regulation and LicenseRegulation and License

- KepMenLH No. 13 Tahun 1995 “Baku Mutu Emisi Sumber Tidak Bergerak”.

- KepMenLH No. 48 Tahun 1996 “Baku Mutu Tingkat Kebisingan”.

- KepMenLH No. 50 Tahun 1996 “Baku Mutu Tingkat Kebauan”.

- KepMenLH No. 51 Tahun 1995 “Baku Mutu Limbah Cair Bagi Kegiatan Industri”.

- PerMenLH No. 02 Tahun 2008 “Pemanfaatan Limbah Bahan Berbahaya dan Beracun”.

- PerMenLH No. 03 Tahun 2008 “Tata Cara Pemberian Simbol dan Label Bahan Berbahaya dan Beracun”.

- KepBapedalda No. 05 Tahun 1995 “Simbol dan Label Bahan Berbahaya dan Beracun”.

- KepBapedalda No. 691 Tahun 2006 “Rekomendasi Persyaratan Kualitas Air Limbah Kegiatan PT. Toba Pulp Lestari, Tbk.


Regulation and LicenseRegulation and License

B. License- KepMenLH No. 207 Tahun 2008 “Izin Penyimpanan

Limbah Bahan Berbahaya dan Beracun di HTI”.- KepMenLH No. 351 Tahun 2008 “Izin Pemanfaatan

Limbah Bahan Berbahaya dan Beracun Untuk Stabilisasi Slab di Lokasi Log Yard dan Pengerasan Jalan di HTI Serta Bahan Pengoreksi pH.

- KepMenLH No. 435 Tahun 2006 “Izin Penyimpanan Limbah Bahan Berbahaya dan Beracun Kepada PT. Toba Pulp Lestari, Tbk”.


Analysis Water (Waste Analysis Water (Waste Water/River Water) and Water/River Water) and

Emission.Emission.Analysis Waste Watera. BOD (According to government

requirement)

b. COD(According to government requirement)

c. Color(According to government requirement)

d. Total Solid Suspended (TSS) (According to government requirement)

e. pH(According to government requirement)

f. Temperature (Monitoring)

g. Conductivity (Monitoring)

h. S2- (Monitoring)

i. NH3 (Monitoring)Apr 18, 2023 Nurmay Siska Rosilawati Siallagan 19

j. PO4 (Monitoring)

k. NO3 (Monitoring)

l. NO2 (Monitoring)

m. MLSS (Monitoring)

n. Cl2 (Monitoring)

o. SVI (Suspended Volume Index) (Monitoring)

p. N-Tot (Monitoring)

q. Na (Monitoring)

r. Ca (Monitoring)

s. Cl- (Monitoring)

t. SO4 (Monitoring)

Analysis River Water/ Bore Well

• PO4

• Mn • Fe • Na• Ba • Ca2+

• NO3

• NO2

• NH3


l. pHm. Temperaturen. CODo. BODp. Colorq. TSSr. Zn s. Cl-

t. Cl2u. Turbidity

Analysis Emission

• Particulate

• Total reduce sulfur (TRS)

• Chlorine (Cl2)

• Chlorine dioxide (ClO2)

• Sulfur dioxide (SO2)

• Nitrogen dioxide (NO2)

• Opacity


Symbol And Label B3Symbol And Label B3

Regulation be related about B3 waste :1. PP No. 18/1999 about B3 waste treatment.2. Permen LH No. 03/2008 about arrangement to give

symbol and label B3.3. Keputusan Menteri Perindustrian No. 148/1985 about

safety of dangerous and poison material in industry company.

4. Keputusan Menteri Tenaga Kerja No. 187/1999 about controlled dangerous chemical material in job area.

5. Undang-Undang No.32/2009 about environmental management and protection.


Definition of B3:Hazardous is material which because characteristic and/or it concentration and/or it amount, as well as direct will to indirect, can pollution and/or damage environmental, and/or can danger of environmental, healthy, humanity live, and other live of creature .(Permen LH No. 03/2008 about arrangement to give symbol and label B3)

Criteria of B3 waste (PP. No.18/1999):- Easy to explode.- Easy to burner.- Reactive.- Toxic.- Infeksius.- Corrosive.



Easy to Explode Oxidation Flammable Poison Dangerous

X

Irritation

Hazardous to

EnvironmentCorrosive Pressure

GasKarsigonic,Tert

agonic, and Mutagenic

http://www.sitehawk.com/images/ghs_pictograms/explos_lg.gif

http://www.sitehawk.com/images/ghs_pictograms/rondflam_lg.gif

http://www.sitehawk.com/images/ghs_pictograms/bottle_lg.gif

http://en.wikipedia.org/wiki/Image:GHS_carcinogen_sign.svg

Label Identify of B3:Label Identify of B3:


Name B3/ name of Name B3/ name of tradetrade

Information handle of Information handle of action.action.

Additional information

Identity of pemasokIdentity of pemasok

Name B3Name B3

(Composition, No. (Composition, No. CAS/No. UN) CAS/No. UN) ProdusenProdusen-Danger declaration :Danger declaration :Classification of B3Classification of B3Fisik, health and Fisik, health and environmental.environmental.

Example of label identify

Label of placement (Kepmennaker No. 187/1999) : Put the label in place which easy to know by employee

and matters pertaining to manpower supervisor employee.

Drum to liquid and solid waste:


coverRubber (packing)Ring key

Label

Symbol

Limbah Cair Limbah Padat

Solid Waste Management


Solid Waste

Mill :Barks, under size chips, dust, dregs, grits, lime mud, sludge, ash boiler, mercury lamp, wet cell, COD bottle,

etc

Office :Toner catridge, paper,

pens, and other biodegradable waste

Clinic and Town Site :Infuse bottle, gauze, household waste, etc

Characteristic of B3?

-Sorting Plant: segregation in organic (sold) and organic to be compost.-- used concrete road, stabilization.-- Landfill or Dumpsite.

NO

Send to B3 house

Send to Authorized

YES

finish

Can be manage of

B3?

NO

3R (Reuse, Recycle, Recovery)

YES

Proposed ImprovementProposed Improvement

Problem statement: If sludge from secondary treatment burnt in boiler that ash from boiler can’t send to HTI before treatment to fertilizer in plantation. According to regulation government ministry letter that sludge and ash must treatment previously and then send to HTI as fertilizer in plantation.

Target improvement :Composting sludge and ash as fertilizer in plantation.



Input – Process – Output

If sludge burnt in boiler that ash can’t send to sector

PT. Toba Pulp Lestari,Tbk

utilization sludge and ash as compost Compost

Scope of Process

Process description :Utilization sludge and ash as compost, start with determine location and people to do this process, determine method of composting, serve instrument, make standard operation procedure (SOP) compost, serve microorganism, Implementation to fertilizer in plantation.

Data BeforeData Before

No Description Unit

1 Total of effluent sludge / months Ton

2 Method of sending to Multi Fuel Boiler every day

3 Ash boiler to sector (mix with effluent sludge) every day

Ton

4 Ash boiler to sector (without mix with effluent sludge) every day

Ton


LiteratureGraydon. A. R. H, “Composting Of Pulp and Paper

Mill Power Boiler Fly Ash with Wastewater Treatment Sludge”, Thesis, 1998

Process Analysis


Problem identified during process :1. Extension license from government

environmental ministry to send ash boiler in sector.

2. If sludge burnt in MFB, so ash from MFBcan’t send to sector direct.

3. More many ash still there in the sector landfill in comparison with using as fertilizer.

4. Ash and sludge using as fertilizer is little.5. Not take care environmental as well as

to care environmental.

Agree from government

Sludge storage

by periodic at 15 days

sludge burnt in MFB

Ash send to sector

Ash as fertilizer in plantation

A

A

Checking of using ash as fertilizer

Finish

Composting

The method of compost making process is windrow.


1 m2 m 1 m

2 m 1 m2 m

2m

10-15

m

* Assumption Sludge generate = 700 Ton/Month (MC= 70%)* For 40 % MC of sludge = 350 Ton/Month.* Total composting = 0,6x350 = 210 Ton/Month = 7 m3/Day.* Conduct of composting every three days with pile measure 2x15x1 = 30 m3.* Pile size is 4x16 = 64 m2, with assumption 3 months composting time.* The area will be need are: 30 x 64 = 1920 m2, above 2000 m2 (100m x 20m).* The are use concrete floor with leachate collection system.* Create SOP of composting.

Detail Of Buildings

Price Of Building

s

COMPOSTING PROCESS


What is the decomposer for

composting process?

What is the decomposer for

composting process?

From literature that available nutrients in the compost shown in below:


Component Soil targets Final compost with turned windrow

PhosphorousPotassium

CalciumMagnesium

CopperZinc Iron

Manganase Boron

Sulfate-sulfurSodium

AluminumTotal nitrogenOrganic matter

Total sulfur

150250

20002501025

150501

255010

0.55010

0.05

119970

30005500.6

16.23

3154.2

12.613001500.6357.80.32

Data from literature and data ash and sludge TPL

From literature that initial and final pH, moisture content, % N of compost :

Compost Ash only Sludge only S:A 2:1 S:A 1:1

pH

Initial Final

9.279.32

9.238.68

8.858.22

8.858.37

MC

Initial Final

40.2736.98

71.5460.25

54.7353.92

56.2448.83

%N

Final 0.15 2.14 1.16 0.59

Implementation1. Manage solid waste such ash boiler and sludge to be compost.2. To change using chemical fertilizer with using compost in plantation.

3. Reduce negative impact environmental in surrounding mill area.

Cost AnalysisBenefit of compost to get good image that our company care with environmental.


Total Cost of Composting

Conclusion

1. Every process generate waste include waste water, solid waste and emission.

2. Every waste generated must be control correct to Government Requirements.
