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WELCOME

WELCOME. Hindustan Newsprint Ltd Presentation by: M.G Sreekumary, Manager (Energy). Profile. A Government of India Company under Department of Heavy Industry, Ministry of Heavy Industries and Public Enterprises

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WELCOME

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  1. WELCOME Hindustan Newsprint Ltd Presentation by: M.G Sreekumary, Manager (Energy)

  2. Profile • A Government of India Company under Department of Heavy Industry, Ministry of Heavy Industries and Public Enterprises • Installed capacity of 80,000 MT - 1982. Capacity enhanced to 1,00,000 MT - 1995-96. • Capacity Utilization 112%.Potential for Utilization of 115%.Highest market share and market value.

  3. Quality and Environment • ISO 9002 certification for Quality Management System in the year 1998 • ISO 14001 for Environment Management System in the year 2000. • HNL township also certified for ISO 14001 • Re-certified under ISO 9001:2000 Quality Standards in November 2002 • Awarded “Two Green Leaves” among Indian Pulp &Paper Industry under Green Rating Project by Center for Science & Environment.

  4. Process-Newsprint Production CHEMI-MECHANICAL PULPING PLANT Wood Reed/ Bamboo CHEMICAL PULPING PLANT PAPER MACHINE DE-INKING PULP PLANT Waste Paper PURCHASED PULP NEWSPRINT

  5. Key Business Drivers • Reduce Cost • Improve Quality • Reduce Wastage • Increase Efficiency CONSERVATION OF RESOURCES

  6. Energy Conservation Potential-India • Iron & steel -- 10% • Fertilizer -- 15% • Cement -- 15% • Aluminium -- 10% • Textiles -- 25% • Petro Chemicals -- 15% • Refineries -- 10% • Pulp & Paper -- 25% Source:Website-BEE

  7. Energy Conservation Potential-HNL Energy Cost: 38 % of the Variable Cost Energy Cost: 29 % of the Total Cost

  8. Energy Conservation Potential-HNL

  9. Energy Management : - Structured Mechanism • Strategic Corporate Plan • Energy Policy • Designated Energy Manager • Energy Management Cell • Energy Management Tools • Energy Audits & surveys

  10. Objective – Monitor, Analyse and Improve Review- Daily at Operational Level Weekly at Management Level Monthly at Apex Level Energy Management Cell Members - Representations from all Functional areas. Energy Management System

  11. Collective efforts Team approach • Periodic brain Storming sessions • Suggestion scheme • Participative approach in • Review • Implementation • Specific Task forces for each • initiatives

  12. Centralized Energy Monitoring System - Enercon eLAN system Energy Management Tools

  13. Energy Management Tools- Contd.. Integrated Management Information System – ERP (BaaN IV) ………………..Paper for Views………….

  14. Energy Audit • External: Conducted by SPB PC in 2002, Next audit planned for 2005. • Internal: Yearly Internal audit by our EM Cell. Survey of Thermal Insulation. Efficiency Tests of Equipments .

  15. Energy Policy • Create awareness among all employees to conserve energy • and natural resources • Monitor closely and control consumption of various forms of • energy through an effective energy management system. • Optimize the ratio of grid to captive power. • Reduce specific energy consumption • Upgrade technology and improve efficiency of equipment • and process. • Enhance efficiency of steam generation. • Reduce coal consumption by utilization of non conventional • fuels for steam generation. • Carry out external energy audits periodically to identify areas • for continual improvement

  16. Awareness Campaign In-House Training Programme More than 80% Employees are already given awareness on EC Act, Energy Conservation Projects . External Programmes Training at Kerala State Productivity Council. TERI , Forbes Marshall, CII, NPC etc. Energy Seminars Energy Summit 2003& 2004 by CII, Energy Meets Employee Participation Suggestion Schemes, Interactive Task Forces Energy Conservation Week Energy Quiz, Technical Sessions etc. Campaign among colony occupants Competitions,Technical sessions

  17. Encon Activities Year of Focus: 2003-04

  18. Encon Achievements: 2003-04 • 10 % Reduction in sp.electrical energy • 3.7% Reduction in sp.thermal energy • 34 % Reduction in sp.furnace oil consumption • 11 % Reduction in sp.water consumption

  19. Kerala State Energy Conservation Award - 2004

  20. …….Encon Achievements Specific Electrical Energy Consumption(kWh/MT of Newsprint)

  21. …….Encon Achievements Specific Thermal Energy Consumption(in Million Kcal / MT of Newsprint)

  22. …….Encon Achievements

  23. …….Encon Achievements Specific Furnace Oil Consumption(L/ MT of Newsprint)

  24. Pulp Furnish Optimisation • Partial substitution of energy-intensive Chemi-Mechanical pulp & Chemical pulp with De-inked pulp. Specific Energy-Pulp Grades

  25. ….. Pulp Furnish Optimisation Annual Saving : 132 Lakh units

  26. Total Process Automation • Totally Integrated Process Control System (DCS) for the Mill. Innovative solutions through logic changes,optimisation packages etc. • State- of -the -art Quality Control System (QCS) for the end product. Stabilisation and optimisation of Induction Calcoil system Annual Saving:17 Lakh units

  27. Usage of Non- Conventional Fuels Wood FinesCashew Nut Shell Effluent Sludge

  28. Fuel Substitution • Saving of 5558 MT Coal by usage of non- conventional fuels. • Annual Saving : Rs 95 Lakhs

  29. Demand Control • Contract Demand with KSEB reduced from 30 MVA to 26MVA from Nov. 2003. • Maximum demand restricted to 19.2 MVA from 22 MVA • Annual Saving: Rs 84 Lakhs

  30. Optimisation of Co-generation Purchased Electrical Energy(Lakh kWh) Co-generation - TG(Lakh kWh)

  31. Efficiency Improvement • Substitution of 2 nos of cooling water pumps by a single pump fitted with higher diameter impeller. • Investment : Rs 1, 35,000. • Annual Saving : 4,15,140 units • Annual Saving : Rs 14.95 Lakhs

  32. Technology Up gradation Variable Frequency Drive for Wet End drives Cooling Fan in Paper M/c. • Annual Saving : 1,18,800 units • Annual Saving : Rs 4.27 Lakhs.

  33. Energy Efficient Equipments • 45KW Broke Chest Agitator with 37KW Sulzer agitator. Investment : Rs 11 Lakhs Annual Saving : 1,54,800 units Annual Saving : Rs 5.57 Lakhs • Replacement of Incandescent Indication Lamps with LED Lamps in Paper Machine plant. Investment : Rs 1,62,000 Annual Saving : 7920 units Annual Saving : Rs 31. 504/-

  34. Capacity Optimization Replacement of 7.5 KW, 3000 rpm motor with 3.7 KW 1500 rpm motor with VFD (Soup Pump to CP). Investment : Rs 5 Lakhs Saving in units : 21,250 kWh Saving in Cost : Rs .76, 500

  35. Energy Conservation Survey Study by External Technical consultant during September 2003. • Target: Identifying Energy Saving Potential in Motors, Pumps & Fans. • Result: Identified 60 motors ,Pumps & Fans with potential to reduce energy cost by 38 % • Method: Introduction of Variable Frequency Drives.

  36. Schemes initiated- 2003-04 Variable Frequency Drives for 45 drives in two phases. • Total Investment : Rs 350 Lakhs • Expected Savings : 52.82 Lakh kWh. • Status: : All the 45 drives commissioned Energy Saving Per Day: 17,000 units

  37. …….Schemes initiated- 2003-04 Trim Pulper with Cyclone Separator Investment : Rs 26 Lakhs Expected Saving : 2.31 Lakh units Status : Commissioned in October 2004

  38. …….Schemes initiated- 2003-04 • Installation of Energy efficient Pumps • 400KW Secondary Cleaners Pump by 250KW Sulzer Pump. • Investment : Rs 18.13 Lakhs • Expected Saving : 7.44 Lakh units • Status: : Commissioned in January 2005. • 110KW Liquor Circulation pump with 90KW Sulzer Pump. • Investment : Rs 13.77 Lakhs • Expected Saving : 52,800 units • Status : Commissioning by March 2005.

  39. Future Ahead • Reduction of Specific Electrical Energy from 1859 to 1800 units by 2006. • Reduction of specific thermal energy from 5.1 to 4.7 by 2006. • Bio methanation of effluent for using the generated methane in place of furnace oil in Lime reburning plant by the year 2008.

  40. Thank you…

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