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IPPTA ZONAL SEMINAR ENERGY CONSERVATION BY OPTIMISING OPERATIONS AND IMPLEMENTING ENERGY SAVING IDEAS

IPPTA ZONAL SEMINAR ENERGY CONSERVATION BY OPTIMISING OPERATIONS AND IMPLEMENTING ENERGY SAVING IDEAS. (An ISO 9001:2000 Certified Unit). Ballarpur Industries Limited Unit Ballarpur. 13-14 th July 2006. About Bilt Unit Ballarpur ….

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IPPTA ZONAL SEMINAR ENERGY CONSERVATION BY OPTIMISING OPERATIONS AND IMPLEMENTING ENERGY SAVING IDEAS

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  1. IPPTA ZONAL SEMINAR ENERGY CONSERVATION BY OPTIMISING OPERATIONS AND IMPLEMENTING ENERGY SAVING IDEAS (An ISO 9001:2000 Certified Unit) Ballarpur Industries Limited Unit Ballarpur 13-14th July 2006

  2. About Bilt Unit Ballarpur …. • Bilt Ballarpur is an integrated Pulp and Paper Mill located at • Ballarpur in Chandrapur district on the pit head of WCL coal • mines. • It has produced 1,26,000 MT of writing and printing paper in • 2005-06. • Annual sales turnover was 518 Cr. in the year 05-06.

  3. Glimpses of Ballarpur Industries LimitedUnit Ballarpur

  4. Mills Main Gate and Panoramic View

  5. Raw material Feeding in Chipper Chipper

  6. Pulp Mill Pulp Mill With DCS Control Washing & Bleaching

  7. Paper Machine & Finishing Paper Machine N0.3 Paper finishing & ware house

  8. Power Plant Boiler House Turbine Captive Power Generation 96% (25.5 MW)

  9. Energy Scenario • Energy - a most vital resource for human life. • Energy efficiency is important for reducing global warming. • There is increasing demand of Power in the country with • an average short fall of 7 to 12%. • Pulp & Paper Industry is highly energy intensive industry. • Bilt Ballarpur meets 96-97% of its power demand by own • co-generation plant. • Energy Cell at Ballarpur is functioning since 1980’s • TQM methodology is adopted to explore ENCON ideas and • ensure implementation.

  10. Energy Cell Set up VP (op) CGM Energy Manager EC Core Team Deptt Teams Energy Conservation Measures Identification & Implementations Audit & Control of Savings Weekly & Monthly Energy Data Collection & MIS Energy Awareness Programmes

  11. Mill Performance

  12. Paper Production Lac T / annum

  13. Energy Cost (% of total Manufacturing Cost) Energy Cost Energy Cost Energy Cost Energy Cost 2004-05 and 05-06 increase is due to impact of coal price

  14. Ideas Implemented & Savings Achieved

  15. Last Few Years Energy Savings & Investment

  16. Energy Conservation Achievements Direct Pumping of Pulp from Un-Bleach HD Tower to Primary fractionator and shutting down one Pump. Power saved – 289800 kwh /yr Saving – Rs. 6.29 Lacs Investment – Rs.0.20 Lacs Enhancing the capacity of single Vacuum Pump in place of two pumps for couch on Paper Machine No.2 Power saved – 352800 kwh /yr Saving – Rs. 7.66 Lacs Investment – Rs.0.30 Lacs POWER SAVING INITIATIVES Shutting down one Propeller of PM-3 Under Pulper Power saved – 332640 kwh /yr Saving – Rs. 7.22 Lacs Investment – Nil

  17. Energy Conservation Achievements Installation of Variable Frequency Drive in 2 Nos. Shrink Bundling Machine Power saved – 54600 kwh /yr Saving – Rs. 1.18 Lacs Investment – Rs.0.60 Lacs Modification of grit re-firing system in coal boiler No.7 and 8 Power saved – 29700 kwh /yr Saving – Rs. 0.64 Lacs Investment – Rs.0.25 Lacs POWER SAVING INITIATIVES Modification of ash handling belt No. 3,4, and 5 by providing single belt conveyor as by pass arrangement. Power saved – 59400 kwh /yr Saving – Rs. 2.29 Lacs Investment – Rs. 1.50 Lacs

  18. Energy Conservation Achievements Shutting down one De-super heater pump by direct feeding thr’o Boiler feed pump. Power saved – 29700 kwh /yr Saving – Rs. 0.64 Lacs Investment – Rs.0.25 Lacs Repositioning of PM-5 vacuum pump silencer. Power saved – 40320 kwh /yr Saving – Rs. 0.87 Lacs Investment – Rs.0.10 Lacs POWER SAVING INITIATIVES Installation of 2000 KVAR capacitors for maintaining the power factor Saving – Rs. 10 Lacs Investment – Rs. 10 Lacs

  19. Energy Conservation Achievements Grinding of PM-3 Dryer cylindersresulted in reducing specific steam consumption & fiber saving. Coal Saved – 2268 T Fiber Saved – 274 T Saving – Rs. 60 Lacs Investment – Rs.150 Lacs Installation of on line QCS on PM-4 for better control of moisture & basis weight resulted in saving of fibre. Fiber Saved – 92 T Saving – Rs. 10 Lacs Investment – Rs.30 Lacs STEAM SAVING INITIATIVES Installation of feed water heater in Coal Boiler no. -4 & 6 resulted in coal saving. Coal Saved – 1416 T Saving – Rs.19 Lacs Investment – Rs.5 Lacs

  20. Energy Conservation Achievements Replacement of old inefficient Cl2 Compressor in CSC plant resulted in power saving Power Saved – 87579 kWh/ yr Saving – Rs. 1 Lacs Investment – Rs.3 Lacs Replacement of inefficient rotor of warm water pump in Pulp mill resulted in power saving Power Saved – 252000 kWh / yr Saving – Rs. 3 Lacs Investment – Rs.0.75 Lacs POWER SAVING INITIATIVES Optimizing Refiner operations by running of 0.5SDM in place of 0SDM on PM-6 resulted in power saving Power Saved - 212900 Saving – Rs. 2.55 Lacs Investment – NIL

  21. Energy Conservation Achievements Optimization of Operations by running single DDR at PM-3 during Higher GSM Power Saved - 679800 Saving – Rs. 8 Lacs Investment – Nil Repositioning of PM-6 Vacuum Pump Silencers to save Power Power Saved - 249200 Saving – Rs. 3 Lacs Investment – Rs.0.50 Lacs POWER SAVING INITIATIVES Reduction in water consumption Reduction in power consumption for water by reducing water consumption Water Saved – 12.01 lac m3 Saving – Rs. 12.0 Lacs Investment – NIL

  22. Specific Energy Consumption

  23. Electrical Energy Consumption kWh / T of Paper

  24. Thermal Energy Consumption M kCal / T of Paper

  25. Water Consumption m3 / T of Paper

  26. Employee Training, Participation & Motivation

  27. Awareness Programmes for employees & their involvement Mass communication & awareness programmes Awareness programmes are conducted on regular intervals. Employees are presenting their Projects

  28. Energy Conservation Week “ENERGY CONSERVATION WEEK” CELEBRATED FROM 14th to 20th Dec, 2005 Awareness programme by PCRA Energy Quiz Competition Slogan Competition Painting Competition by Children Prize Distribution vat-maana kI hO , yahI pukar ! ibajalaI, panaI na jaayao baokar !!

  29. Future Technology & Energy Plans

  30. Future Plans • Replacement of spreader stoker type coal boiler with CFBC boiler to improve boiler efficiency and use cheaper quality coal. • Higher pressure cycle of Boiler and turbines (existing 37 kg/cm2 g and 425o C) • Installation of energy efficient high capacity Recovery boilers of 1200 TBLS with latest technology FFFF type evaporators. • Installation of producer gas plant in new 180 TPD limekiln, which will be installed this year. • Installation of new high capacity paper machine and stop operations of small multiple Paper machines to improve quality, productivity and reduce usages of chemicals additives and other inputs.

  31. National & State Level Awards

  32. National & State Level Awards

  33. Conclusion • Energy consumption in Indian pulp and paper mills is on • higher side. • Increasing energy cost and depleting resources are major • concerns • Energy Conservation Opportunities are to be identified and • communicated in the organization. • Workers Participation is must. • Introduce site-specific conservation measures & re- • examine their effectiveness periodically. • Promoting a culture of innovation & creativity in order to • reduce specific energy consumptions continuously.

  34. Conclusion • Reducing wastage through optimizing operations. • Continuous system improvements and up-gradation is • necessary. • Workout feasibility of technology up-gradation. • Paper mills should share their ENCON success story for • this National cause and to conserve the vital natural • resources. • Bilt is working out on many up-gradation in co-generation • and pulping process for improving environment and energy • efficiency.

  35. We are Committed to Conserve Energy by Motivating Our People for Optimal Use OfTechnology and Natural Resourcesat an Affordable Cost

  36. THANK YOU

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