MODERN CARDBOARD CORPORATION

1. MODERN CARDBOARD CORPORATION 15/01/2010 PREPARED BY : M. MERIH AYDIN BARIS TOR RANA OKUR GOZDE YILMAZ

2. Modern Cardboard Corporation Sector: Corrugated Cardboard Year of Establishment :1981Production Capacity : 700.000 tons/yearClosed Area :130.000 m²Open Area :530.000 m²Number of Employees :440

3. Modern Cardboard Corporation • Manufacturingtechnology, • Automationsystem → the most advanced technologies in the paper industry. • Majorpaper manufacturer in Europe. (700.000tons/year)

4. Modern Cardboard Corporation • Paperexports 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.

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

6. PRODUCTION PROCESS

7. PRODUCTION PROCESS • Raw Materials used: • Water • Waste Cardboard • Products: • Kraft Paper • Cardboard • Corrugated Cardboard

8. PRODUCTION PROCESS Additives: • Bleaching agents • Starch • Calcium Carbonate • Sodium Hydroxide • Sulfur Compounds

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

11. PRODUCTION PROCESS

12. PRODUCTION PROCESS

13. WASTEWATER TREATMENT PLANT

14. Modern Cardboard Corporation • Units of wastewater treatment plant • Primary Sedimentation • Equalization Tank • Anaerobic Reactor • Aerobic Reactor • Secondary Clarifier • Sludge Dewatering

15. Modern Cardboard Corporation • Primary Sedimentation : to remove& reuse SS (fıbers)and important in terms of decreasing organic load and recycling of paper fiber Primary Sedimentation Initial WW Pulp Production Recovered Fiber

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 cheapesttreatment technology for paper industry.

17. Modern Cardboard Corporation • Wastewater produced in industry ranges from 4000 to 6000 mg COD /L • Activatedsludge processand mechanical aerated tanksare used. • High strength wastewater streamsis sent to anaerobic systembefore aerobic system to decrease aeration cost and operational cost.

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 boilerto produce heat. • Thıs is method is environmental friendly &cost effective technology

19. Up flow Anaerobic Sludge Reactor Biogas Storage BOILERS Influent waste stream

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.

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 dewateringlime addition, 30-35 % solids containing sludge production. • Sludge cake is transferred to municipality landfill for ultimate disposal.

23. WASTE CHARACTERIZATION

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.

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.

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 coconutfibres.

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.)

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.

29. REFERENCES • http://www.erenholding.com.tr/sectors/paper/modern_karton • http://www.training.gpa.unep.org/images/jpg/upflow_anaerobic_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, 4th Edition, page: 687, table 8.7. • Wastewater Engineering: Treatment and Reuse, Metcalf and Eddy, 4th Edition, page: 1565

30. THANK YOU 