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There is a sense in some markets that the paper and pulp industry will decline owing to the digital technologies with which people interact every day. While this might be considered logical, the reality is completely different. In fact, the paper and pulp industry has experienced a steady growth and will continue to do so in 2021.

Production of paper increased by more than 450% in the last decades and the demand of paperboard in the world is expected to grow significantly, driven by e-commerce and big retailers increasing their presence in the online sales universe. This sustained growth in production capacity and paper consumption presents several fire risks to companies and exposes communities that develop around paper mills, to the impact of disasters caused by these fire risks.

Fire risks in the paper and pulp industry

Paper and cardboard are combustible, but this is not the only fire risk found in these types of industries. Raw materials and finished goods storage are sensitive to fire. In addition, the paper making process includes several stages where fires can occur, due to hot surfaces or poor ventilation. The most relevant fire risks on a paper plant are:

  • Storage Areas: As mentioned before, paper and cardboard are combustible. Solid paper blocks and reels have hard surfaces that don’t ignite easily, but usually these reels can suffer minor damages or have loose sheets that significantly increase the fire risk.

When paper reels are stacked in columns, gaps in the center can act as chimneys and when fires start in the bottom of the stack, this chimney effect will accelerate smoke and hot air spread, increasing vertical and horizontal flame spread.

Wood and Bale storage fire risks

Bale storage also presents a high fire risk, as loose materials are always present

Raw materials for the paper making process can have two main sources, forestry products (mainly wood) or recycled cardboard and paper. Wood storage presents several challenges, especially due to wood chips that are highly combustible and, in some cases, even explosive.

Bale storage also presents a high fire risk, as loose materials are always present. Fire in baled paper is difficult to extinguish and generates heavy smoke. In many recycling facilities, these paper bales are stored outdoors, where paper or rags soaked in flammable liquids, embedded between the paper sheets, can ignite resulting in a fast spreading fire.

Chemicals, flammable liquids and gases

In addition, it is possible to find different types of chemicals, flammable liquids and gases that are used in the paper making process. These materials have their own fire-related risks that need to be taken in consideration.

  • Production Areas: In pulp factories, there are several long-distance conveyors that transport wood and wood chips. These conveyors constitute a fire risk and the most probable causes of fire are bearing damage, overheating of the conveyor and igniting chips in the environment.

IR dryers, a common source of fire

After the wood has been transported, chipped and digested, the paper making process becomes extremely humid, due to the large amounts of hot water and steam needed. But, as soon as the pulp fiber sheet starts to dry, the hot surfaces in contact with the paper sheets can be a source of ignition. IR dryers used in the process are also a common source of fire in the paper industry.

When the sheet of paper is formed, close contact with reels and bearings moving fast can create static electricity that could ignite loose paper or airborne particles. Problems like these are likely to be more extensive in tissue mills. Paper dust is generated in certain parts of the process, especially where paper shits are slit or cut.

Poorly insulated steam pipes lead to fire

Poorly insulated steam pipes can ignite paper dust or even their own insulation materials. In addition, paper dust gathers in the ventilation grills of machinery, causing overheating and igniting as well.

Heated oil is used in several parts of the process as well and if a malfunction occurs on the Hot Oil Roll systems, leaks might occur, exposing hot surfaces to this oil and causing ignitions. A paper mill has hydraulically operated machinery, where leaks or sprays might ignite as well.

  • Service Areas: As in many other manufacturing facilities, several service areas can be found. Electrical and network equipment rooms have an inherent fire risk due to damaged wires or equipment, overheating or short circuits in high voltage circuits. Transformer and generator areas entail fire risks as well.

High fire risk for boiler rooms

Flammable gas distribution systems can be ignition sources, in case of leaks or damaged pipes or valves

Hot water and steam are key components for the paper making process. For this reason, paper plants use high capacity boilers that can be powered by flammable liquids or gases. A high fire risk can be considered for boiler rooms.

Flammable gas distribution systems can be ignition sources, in case of leaks or damaged pipes or valves. In addition to the fire risks mentioned in these areas, many maintenance operations can also pose fire risk, especially when hot works are being performed.

Sparks caused by welding or the use of certain tools can ignite paper sheets or dust in the air. Poor housekeeping and buildup of paper dust, for example, increases the risk associated with maintenance and construction works.

Prevention, the first line of defense

According to the Health and Safety Executive from the United Kingdom, 60% of fires on paper mills are caused by machine faults and poor housekeeping.

The first line of defense to avoid fire risks in paper plants is prevention. As mentioned before, a high number of fires in these types of facilities occur because of poor housekeeping and machine malfunction. The key is to identify the risks and possible ignition sources, and apply measures to minimize them.

As in many industries, fire protection has two main components: Passive and Active protection.

Passive fire protection measures

Passive measures include fire rated walls, ceilings, and floors in the most critical areas. Chemical storage areas should be physically separated from other dangerous areas, if this is not possible then the walls separating areas should be fire rated and materials must be stored in a way that minimizes the risk of fire spread by radiation or conduction.

Proper compartmentalization and intumescent protection of structural elements should be part of the package as well. Passive measures include proper ventilation and smoke control. As mentioned before, paper dust is a major fire risk, which is why ventilation and cleaning of hoods over the paper machine is important to minimize the possibility of ignition.

Fire resisting construction should be designed with the following goals in mind:

  • Protection of escape routes
  • Form compartments to contain fires that might occur
  • Separate areas of higher fire risk
  • Protect load bearing and structural members to minimize risk of collapse

Sprinkler systems, gas extinguishing systems and hose reels

Active fire protection includes sprinkler systems, gas extinguishing systems and hose reels to support fire brigades

Active fire protection includes sprinkler systems, gas extinguishing systems and hose reels to support fire brigades. Finished goods stored indoors should be protected with sprinkler systems and the same should be considered for chemical storage areas and certain raw materials.

Paper bales, ideally should be protected by sprinklers that are suitably designed to cope with the height and located, in all cases, 3 meters above the level of bales stacked vertically (which should not exceed 5 meters height).

Spark detectors in hoods, pipes and ventilation systems

Dangerous sparks could be generated in several parts of the paper making process, which is why spark detectors must be installed in hoods, pipes, and ventilation systems. Water spray and CO2 systems can be used to protect machinery against these risks.

Means to fight fires, like extinguishers and hose reels, should be provided to support fire brigades. All the elements should be properly identified and all personnel should be trained and made aware of the location of such devices.

Importance of fire alarms

Fire alarms are required in all paper mills and fire alarm call points should be provided in all locations, according to international guidelines, such as NFPA 72 or EN54. The spread of flames and smoke in paper, wood and chemical storage might become extremely fast. For this reason, early detection is critical. Many technologies might be applied in the different areas of a paper plant.

Nevertheless, there are dusty or humid areas where regular heat or smoke detectors might fail under certain circumstances. For these areas, especially located outdoors, innovative state-of-the-art detection solutions might be applied, like Video Fire Detection (VFD).

NFPA 72 standard for flame and smoke detection

NFPA 72 provides guidelines to implement this technology for flame and smoke detection

NFPA 72 provides guidelines to implement this technology for flame and smoke detection, opening interesting alternatives for designers and fire protection engineers. Many EHS managers and fire protection professionals selected VFD, because it is the only fire detection solution that effectively covered their needs.

Many engineers, specialized in fire protection for paper plants, explained that they tested linear heat detection, aspiration smoke detection, IR/UV detectors and even beams, but none of these technologies performed as they needed on the dirtiest or more humid areas.

Video Fire Detection (VFD) solutions

Outdoor storage areas are often unprotected, because deploying flame or heat detection in large open areas can be costly and mostly ineffective. VFD solutions can detect smoke and flames in outdoor conditions, allowing the monitoring and protection of wood and paper bales in large areas.

Fire detection and alarm systems should be designed with the following goals:

  • Minimize risk of fires, including the use of fire detection technology in areas where regular detection technologies cannot be implemented or are not practical.
  • Minimize risk of flame and smoke spread, with state-of-the-art detection algorithms that guarantee fast and effective detection. Also, reliable algorithms minimize the possibility of nuance or unwanted alarms.
  • In case of a fire, fast detection gives occupants life-saving time to reach to a place of safety, before the flames and smoke have spread to dangerous levels.

Global production of paper and pulp reached 490 million tons in 2020, with many industries and markets depended on the paper and pulp supply chain. That is why innovative ways to protect this supply chain, are key to sustain the paper market growth in the future.

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Author profile

Ivan Paredes Tamayo Head of Product Marketing for Latin America – Fire Detection and Life Safety, Bosch Security Systems

Ivan studied Electronic Engineering and Automation and has almost 19 years' experience in the fire prevention and fire detection fields as a chief designer and project manager for several integration companies.

He served as Firefighter and Urban Search and Rescue specialist for the Guayaquil Fire Department for 8 years.

Working as Head of Product Marketing in Bosch Security and Safety Systems, he is responsible for the development of the fire detection business within Bosch, with a focus in strengthening relations with the fire prevention community and authorities in Latin America, promoting fire prevention knowledge for engineers and society, and creating safer buildings.

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