“Energy Conservation in ABIL - PCD ”

1. “Energy Conservation in ABIL - PCD ” BY Sachin Jain Suresh Kumar KP Reddy Ajay Gupta Manjit Tara M/s Abhishek Industries Ltd.,

2. ABHISHEK INDUSTRIES LIMITED PAPER & CHEMICALS DIVISION Products:Writing & Printing Paper, Sulphuric Acid Capacities : Paper - 40,200 TPA, Sulphuric Acid - 100,000 TPA Sales Turnover :163 Cr (p.a)

3. TRIDENT GROUP COMPANIES Abhishek Industries Ltd., • Paper Chemical Division - Paper Mill - Sulphuric Acid Plant • Yarn Division • Terry Towel Division • Sugar Division

4. ABHISHEK INDUSTRIES - PCD… AT A GLANCE • An integrated Pulp and Paper mill situated at Dhaula, Punjab using Wheat Straw as the Raw material • A part of Trident Group of companies • ABIL was established in year 1993 with an installed capacity of 72 TPD of PWP grade with out Soda Recovery Process • Subsequently SRP was established with 165 TPD of Black Liquor solids in 1998 • Presently produces 125 MT of Eco-friendly Printing & Writing Paper varieties using Wheat Straw, an Agro residue as the Raw material

5. PAPER PLANT Year of commissioning 1993 Installed Capacity 72 TPD Existing Capacity 125 TPD

6. SULPHURIC ACID PLANT Year of Commissioning 1997 Installed Capacity 275 TPD CO-GENERATION PLANT Year of Commissioning 1999 Installed Capacity 9.4 MWH

7. SODA RECOVERY Year of commissioning 1998 • Project Cost 27 Crore • Installed Capacity 165 TPD of Black Liquor Solids

8. EXPANSION PROJECT SALIENT FEATURES

9. UPCOMING PROJECT … • To increase the volume of the Paper production up to 1,36,875 tpa and to improve on the economic scale • To acquire wider product mix capability to meet challenges of emerging markets (Surface sized / Pigmented papers) • Installation of new Energy efficient pulping facility to produce bleached pulp with Environment-friendly Pulping process such as Oxygen De-lignification and Elemental Chlorine Free Bleaching • New two stage Causticizing system to facilitate Silica removal / control from the system with Energy Efficient Equipments • Install new Lime Re-burning Kiln • Meet the AOX limit of 1.0 Kg/ MT paper

10. UPCOMING PROJECT … New wheat straw pulping line • Install a new wet washing system ( two streets running in parallel ) system inclusive of sand removal system and clarifier for back water from wet washing stage • Install 2 newMetso energy efficient continuous digesters for 225 BD TPD of wheat straw chemical pulping capacity • Install state–of–the–art washing and screening system to reduce energy and water consumption • Install multi-stage METSO FIBRELINE - ECF bleaching(O-D–E(OP)–D) for target brightness of 87 %ISO with better pulp quality and less water consumption • Conversion of present stationer digesters into hard wood pulping with 100 BDTPD capacity

11. UPCOMING PROJECT … POWER BOILER AND TG SETS • Power Boiler : 02 Nos • Capacity : 130 TPH Fuel : Multi fuel ( Husk, Coal, Lignite etc.) • Pressure : 105 ata at 5100 C • Turbo Alternator : 02 Nos • Size : 20 MW • Pressure : 105 ata at 5000 C • Necessary auxalary sections like DM Plant, Cooling tower, Coal & Husk handling plant & ESP’s etc Meet Charter on Corporate Responsibility for Environment Protection (CREP)

12. WHY ENERGY CONSERVATION ? To achieve the targeted growth of 7%GDP, it would need commensurate input of energy, mainly commercial energy in the form of coal, oil, gas and electricity India’s fossil fuel reserves are limited The known reserves of oil and natural gas may last hardly for 18 and 26 years respectively at the current reserves to production ratio India has huge proven Coal reserves (84 billion tonnes) may last for about 200 years but the increasing ash content in Indian Coal as well as associated greenhouse gas emission are the major concern In the business as usual scenario, the exploitable Coal may last for about less than 100 years

13. ENERGY DEMAND AND SUPPLY • 70% of the total petroleum product demand is being met by imports, imposing a heavy burden on foreign exchange (Rs.80,000 Crores per year) • Country is also facing Electric Power Shortages -Peak shortage 11% - Average shortages 7% • Additional 100,000 MW required by 2012 • Approximately Rs. 8000 billion investment required • Further , the per capita consumption in India is too low as compared to developed countries (just 4% of USA and 20% of the world average). The per capita consumption is targeted to to grow to about 1000 kWh per year by 2012

14. Area Electric (kWh/T) Steam (lbs/T) Water (gal/T) Woodyard 12.3 Nil TMP, Southern Newsprint 3000 (4500) Kraft Mill, Bleached 115 1980 475 ECF Bleach Plant, Kraft 130 710 3170 Caustic Room 40 551 Pulp Dryer 108 2155 608 Recycle 560 Nil Paper Machine, LWC 500 4860 4060 Paper Machine, Newsprint 580 3700 3350 Paper Machine, Liner 360 4700 5400 Paper Machine, P&W 590 6200 Waste water Treatment 320 na nil ENERGY – BEST OF CLASS IN PULP AND PAPER INDUSTRY

15. (per cent) Power consumption Steam consumed Potential savings in power Large mills Small mills Large mills Small mills Chipping 4 6 - - 42 Pulping 22 29 21 11 Stock making 18 25 - 58 12 Recycling Chem. 16 - 44 - 33 Paper making 40 40 35 42 25 ENERGY USAGE PATTERN IN A PAPER MILL IN INDIA

16. LARGE INDIAN PAPER MILLS: ENERGY EFFICIENCIES

17. SUCCESSFUL ENERGY MANAGEMENT TECHNICAL ABILITY MONITORING SYSTEM STRATEGY PLAN TOP MANAGEMENT SUPPORT

18. METHODOLOGY A) Basic data collection on - List of power consuming equipment     - Production capacities of the major equipment & operation B) Measurement of operating parameters of various equipment to estimate operating efficiency C) Analysis of data collected to develop specific energy saving proposals. D) Presentation on the finding of the detailed energy audit.

19. METHODOLOGY E) Identification of machines is done by measuring power rating of the load and type of load F) Information about machines including method of power transmission, loading sequence, source of energy wastage & method of control G) Energy vs. power rated is used for selection of machines for detailed energy audit H)  To identify the methods for energy conservation, following points are considered - Alternate to reduce / avoid energy losses. - Alternate to reduce downtime. - Alternate to optimum selection.

20. IMPLEMENTED ENERGY SAVING ACTIVITIES IN ABIL- PCD

21. POWER CONSUMPTION PATTERN

22. Providing VFD at P.A. Fan of Power boiler - 300 KW Energy saving : 13179 KWh/month Cost saving : 52452 Rs/month

23. Providing VFD at S.A. Fan of Power boiler - 90 KW Energy saving : 6680 KWh/month Cost saving : 26588 Rs/month

24. Providing VFD at S.A. Fan of Recovery Boiler - 37 KW Energy saving : 1150 KWh/month Cost saving : 4578 Rs/month

25. Providing VFD at I.D. Fan of CVL Boiler - 110 KW Energy saving : 19020 KWh/month Cost saving : 75701 Rs/month

26. Interlocking of Couch pit Agitator with level VFD.18.5 KW Energy saving : 2520 KWh/month Cost saving : 10030 Rs/month

27. Replacing the existing 75 KW Depither motor with 37 KW motor Energy saving : 2809 KWh/month Cost saving : 11180 Rs/month

28. Replacing the existing 75 KW motor of Irrigation pump in ETP with 55 KW motor Energy saving : 3881 KWh/month Cost saving : 15448 Rs/month

29. ENERGY CONSERVATION IN ABIL Contd…

30. …Contd

31. …Contd

32. …Contd ABIL is going for new high energy efficient Recovery Boiler to handle dry solids firing at rate of 65 % from purely agro residues and it is first of its kind in India without Cascade Evaporator in Recovery Boiler Installation of Pressure Activated Pump Unit for collection of Trap condensate from every possible drain points Installation of Phase wise Glandless Valves to prevent even small gland leakages in low and medium pressure steam lines The Energy Efficient motors are largely being used in our new installations Installation of Delta Star Starters on Digesters

33. …Contd • Modification in PCC Panel of Paper machine  • Optimization of working of Agitators at ETP • Installation of VFD on Simplex Cutter, Duplex Cutter & Brown Stock Washer • Regular Energy Audits - after analyzing the loading pattern of motors, corrective actions have been taken to improve the efficiency of motors • Installation of Capacitor banks near load center to minimize the line losses • Installation of Flexible Copper links to minimize the line losses

34. …Contd Interlocking of Bucket elevator with Conveyor in Causticizing plant.  Replacing the under loaded motors with lower capacity motors Installation of Variable Frequency drive at Fan Pump of Paper machine Power factor improvement by installation of Capacitors.  Optimization of Vacuum circuitry Connecting some of the under loaded motors in Star connection to improve their efficiency Auto start / stop system for Couch pit Pump of Paper machine Optimization of working of Support insulator heaters in ESP

35. …Contd Power saving by providing step down transformer/ automatic voltage stabilizer in lighting circuit. Total lighting load=250kw Saving anticipated=10-15% Total saving per day =250x0.10x12=300 unitsper day (considering 12 hours running of light load) Installation of 45 KW VFD Variable Torque at ETP agitators Installation of Solar system for preheating of process water Power saving by making a load study of individual motors Power saving by fitting power saver on air conditioner

36. …Contd • Power Factor improvement at load centres i.e. MCC’s thereby eliminating line losses • Installation of 500 KW VFD at ABB Blower • Installation of Cyclic Timers in Submersible pump circuit at paper machine • Power saving by replacing conventional chokes with electronics chokes. Saving per choke=10watt/hour • To conserve Energyby Eliminationof losses and Optimizing the process parameters by initiation of energy conservation steps in various sections

37. ACKNOWLEDGMENTS Our sincere thanks to ABIL management for giving permission to present this Technical paper in IPPTA Zonal seminar, July 2006

38. ENERGY CONSERVATION EFFORTS CONTINUED TRIDENT ON THE MOVE