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CENTURY PULP AND PAPER LALKUA

CENTURY PULP AND PAPER LALKUA. ENERGY CONSERVATION MEASURES 3.09. 2008 V. K. Gururani , Shankariya . CENTURY PULP AND PAPER LALKUA, NAINITAL ( A BK BIRLA GROUP OF COMPANY )

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CENTURY PULP AND PAPER LALKUA

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  1. CENTURY PULP AND PAPER LALKUA ENERGY CONSERVATION MEASURES 3.09. 2008 V. K. Gururani , Shankariya

  2. CENTURY PULP AND PAPER LALKUA, NAINITAL ( A BK BIRLA GROUP OF COMPANY ) ISO 9001: 2000 , ISO 14001:2004,OHSAS 18001 CERTIFIED • AN INTEGERATED PULP & PAPER UNIT • 31320 TPA RAYON GRADE UNIT • 37250 TPA WOOD BASE WRITING PAPER • 84600 TPA BAGASSE BASE PAPER • 75960 TPA RECYCLED PAPER

  3. FLOW DIAGRAM OF Paper Machine

  4. CENTURY PULP AND PAPER POWER ARRANGEMENTS 8.75 LAC UNITS /DAY • 6.8 MW TG SET • 21 MW TG SET • 16 MW T G SET COMMISIONED IN • JAN 2007 • 7.5 MVA CONTRACT DEMAND • FROM UPCL

  5. CENTURY PULP AND PAPER THERMAL ENERGY ARRANGEMENTS 23 TPH 46 Kg/cm2 FBC C F BOILER 3 NO 25 TPH 46/Kg/ cm2 SPREAD ST CF BOILER 1 NO 50 TPH 62 Kg/ cm2 FBC CF BOILER 2 NO 40 TPH 46Kg/ cm2 CHEM REC BOILER 1 NO 50 TPH 62 Kg/ cm2 CHEM REC BOILER 1 NO 60 TPH 62 Kg/cm2 PITH / COAL FIR BOILER1 NO 7100 T/DAY

  6. THERMAL 23.8 % WATER 32.5 % POWER 5.46% HIGH LIGHTS KAIZENS 8750 CHLORINE 7.6 % NEW TECHNOLOGY CAPACITY UTILIZATION 107 %

  7. APPROACH FOR ENERGY CONSERVATION • AWARENESS – EDUCATION & TRAINING • CAPACITY UTILIZATION INCREASED • OPTIMIZATION OF VOLTAGE • OPTIMIZATION OF FREQUENCY • OPTIMIZATION OF OPERATING PROCEDURES • THRUST ON RECYCLE & WASTE MINIMIZATION • FINE TUNING OF PLANTS & EQUIPMENTS • INSTALLATION OF VFD”S • ADOPT ENERGY EFFICIENT LIGHTING • USE OF EFFICIENT EQUIPMENT • TECHNOLOGY UPGRADATION • ASSESSMENT AND MONITORING

  8. ASSESSMENT & MONITORING AUG 2004 - PLANT TECHNICAL AUDITS BY INDEPENDENT COUNSULTANTS MAY 2005 - MOTOR EFFICIENCY ASSESSMENT BY VBI SYSTEMS DEC 2006 - AUDIT CONDUCTED BY CII, 42 SCHEMES IDENTIFIED AUG 2007 - PLANT TECHNICAL AUDITS BY INDEPENDENT COUNSULTANTS

  9. ORGANISATIONAL SET UP FOR ENERGY CONSERVATION Sr PRESIDENT Sr Vice President (Elect & Inst) EC Cell TPM Loss Idn Com ISO 14001/ ISO 9001/QC Energy Centeres * Production *Depart * 3 Members * MR. Shop Floor * Power Hou mental * Cross funct * System Committee & Chem Rec overlapping Teams Coord. # Thermal * Elect&Inst committees * Quality # Electrical * Env & Water Circles # Water * Store,Purchase & Purta

  10. ENERGY CONSERVATION CELL • FUNCTIONS • COORDINATE STEAM & POWER REQUIREMENTS • STUDY VARIANCE • IDENTIFY ENERGY CONSERVATION OPPURTUNITIES • REVIEW ENERGY AUDIT FINDINGS • STRATEGY • INCREASE AWARENESS • ACHIEVE MAXIMUM PLANT EFFICIENCY • INDUCT LATEST TECHNOLOGY • ENSURE TIME BOUND IMPLEMENTATION

  11. TPM A ZERO BASED APPROACH ENHANCE PLANT EFFICIENCY

  12. ZERO BASED APPROACH LOSS FAILURE DEFECT DOUBT ACCIDENT BREAKDOWN 0

  13. AUTONOMOUS MAINTENANCE( JISHU HOZEN ) MY MACHINE I MAINTAIN

  14. EDUCATION AND TRAINING • SKILL DEVELOPMENT : TRAINING PROGRAMME • TPM AWARENESS 28 • TECHNICAL 482 • BEHAVIORAL 38 • FIRE AND SAFETY 605 • ON JOB TRAINING THROUGH ONE-POINT-LESSON SHEET

  15. TPM RE- DEFINED TOTAL POSITIVE MIND TOTAL POSITIVE MIND TOTAL POSITIVE MIND

  16. LOSS IDENTIFICATION COMMITTEE • HIGHLIGHT PROCESS INEFFICIENCIES • CHECK LOSSES OF ALKALI,FIBRE,WATER, CHEMICAL AND STEAM • ARRANGE CORRECTIVE MEASURES

  17. ISO 9001-2000 • CONTINUAL IMPROVEMENT • WASTE MINIMIZATION • ISO14001 • CONSERVATION OF RESOURSES • ADOPTING CLEANER TECHNOLOGIES • ALTERNATIVE FIBRE RESOURSES • UTILIZATION OF WASTE LIME MUD • UTILIZATION OF WASTE PITH QUALITY CIRCLE • 19 CIRCLES OPERATIVE

  18. ONLY MENTAL ENERGY ANNUAL SAVING IN POWER UTILISATIONWITHOUT INVESTMENT

  19. ENERGY CONSERVATION MEASURES • IN ELECTRICAL • PROVISION OF LOAD TRANSFER FROM GRID TO TG WITHOUT INTERRUPTION TO UTILIZE SOURCES • PREVENT IDLE RUNNING OF EQUIPMENTS BY • INTERLOCKING OF PUMPS & AGITATORS • EFFECTIVE CONTROLS LIKE ONE PB FOR A GROUP OF EQUIPMENTS • SWITCH OFF EQUIPMENTS THROUGH TIMERS • INSTALLATION OF VFD FOR VARIABLE FLOW / THROTTLED VALVES • DELTA - STAR FOR LIGHTLY LOADED MOTORS • NEUTRAL COMPENSATORS FOR UNBALANCE LOADS • LED”S FOR INDICATING LIGHTS • LOW LOSS HRC FUSES • USE OF ENERGY SAVERS FOR LIGHTING CIRCUITS • USE OF PHOTO CELLS FOR STREET LIGHTS • SPLITTING OF CIRCUITS FOR BETTER CONTROL

  20. ELECTRICAL ENERGY SAVINGS 2004-05 2005-06 2006-07 2007- 08 NO OF SCHEMES 34 111 75 71 SAVINGS / ANNUM KWH (LACS) 37.29 84.26 29.23 79.89 Rs ( LACS) 76.58 175.15 59.08 159.68 INVESTMENT 84.20 94.30 42.21 374.0 COST OF ELECTRICITY Rs 2.10 Rs 393.9 lacs

  21. ENERGY CONSERVATION MEASURES • IN THERMAL • EFFICIENT MEANS OF HEATING • EFFICIENT HEAT TRANSFER • OPTIMIZATION OF BOILERS FOR COMBUSTION, • FLUE GAS TEMPERATURE, EXCESS AIR • INCREASED UTILISATION OF PITH • MINIMIZE THERMAL LOSSES & WASTAGES • THRUST ON WASTE HEAT RECOVERY

  22. ENERGY CONSERVATION MEASURES • IN PROCESS • CAPACITY MATCHING WITH THE REQUIREMENT • PREVENT IDLE RUNNING OF EQUIPMENT • USE OF CONTINUOUS PROCESS INSTEAD OF • BATCH PROCESS • UPGRADATION OF TECHNOLOGY • USE OF HIGHER EFFICIENCY EQUIPMENT • THRUST ON WASTE HEAT RECOVERY

  23. THERMAL ENERGY SAVINGS 2004-05 2005-06 2006-07 2007-08 NO OF SCHEMES 12 14 10 5 SAVINGS PER ANNUM EQ COAL ( Eq ) 20438 57891 27106 27681 Rs LACS 387.8 1235.7 505.05 512.1 INVESTMENT 444.47 2981.7 1159.1 277.82 COST OF COAL Rs 1850/TON Rs 2253 lacs

  24. TOTAL ENERGY SAVINGS FOR LAST 3 YEARS 2004-05 2005-06 2006-07 2007-08 INVESTMENT 528.9 3076.0 1201.3 1025.84 (LACS) KWH 37.29 84.26 29.23 79.89 (LACS) COAL EQ. 20438 57891 27106 27681 (TONS) Rs LACS 464.4 1410.8 564.1 671.8 Rs 5303 lacs Rs2647 lacs Cumulative Savings

  25. SPECIFIC POWER CONSUMPTION kWhr/ T( Total for RGP, WOOD , BAGASSE & RECYCLED PAPER ) 70 KWhr/T

  26. SPECIFIC STEAM CONSUMPTION T/T ( Total for RGP, WOOD , BAGASSE & RECYCLED PAPER ) 2.17 T/T

  27. COMPARISION WITH NATIONAL STANDARDS ENERGY (POWER & STEAM) CONSUMPTION NORMS (as recommended by CPPRI under EC ACT 2001) WITH IN BATTERY LIMITS ELECTRICAL kwh/T 1197.71 STEAM T/T 9.15 OUTSIDE BATTERY LIMITS ELECTRICAL kwh/T 124.64 STEAM T/T 1.20 TOTAL ELECTRICAL kwh/T 1323.35 STEAM T/T 10.35 1213 Kwh/t 6.93 T/t

  28. INNOVATIVE SCHEMES • OPTIMIZATION OF SOFT WOOD REFINER OPERATIONS • DEFLAKER CHEST LEVEL INTERLOCK • DOCC FILTER • UTILIZATION OF BIOMASS WASTE • REPLACEMENT OF WORM & GEAR ARRANGEMENT BY GEARED MOTORS

  29. OPTIMIZATION OF SOFT WOOD REFINER OPERATIONS SOFT WOOD REFINER BAGASSE STREET OPERATES AT 50% SOFT WOOD REFINER WASTE PAPER STREET

  30. OPTIMIZATION OF SOFT WOOD REFINER OPERATIONS SOFT WOODREFINER ANNUAL SAVINGS ENERGY 2.75 lac kwh Rs 5.24 lacs BAGASSE STREET SOFT WOOD REFINER WASTE PAPER STREET

  31. DEFLAKER CHEST LEVEL INTERLOCK (Waste paper street) 80% level COMMIX Dry Broke Tower Cyclo Screen Deflaker Deflaker chest

  32. DEFLAKER CHEST LEVEL INTERLOCK (Waste paper street) 80% level COMMIX Deflaker chest Energy Savings 0.735 lac kwh Rs 1.47 lacs Dry Broke Tower Cyclo Screen Deflaker ADDITIONAL SAVINGS IN BAGASSE STREET 1.38 lacs kwh Rs 2.76 lacs

  33. DOCC FILTER WASH WATER SHOWER WIRE GETS CHOKED DRYNESS REDUCES LIME MUD SLURRY ROLL CONVEYOR VACUM TYPE FILTER 45% DRYNESS

  34. DOCC FILTER 4 Nos HIGH PRESSURE MOVING NOZZLES WASH WATER SHOWER INVESTMENT 220 lacs SAVINGS Rs 100 lacs LIME MUD SLURRY ROLL CONVEYOR DOCC TYPE FILTER 60% DRYNESS CONTINUOUS CLEANING AND MAINTAINING HIGH POROSITY OF WIRE

  35. DIVERTOR FOR PITH CONVEYOR BAGASSE 1200 TONS/DAY YARD STONES MIXED WITH PITH 65% FIBRE 35% PITH BOILERS PITH STORAGE

  36. DIVERTOR FOR PITH CONVEYOR INVESTMENT Rs 0.5 LACS SAVINGS Rs 14.95 LACS BAGASSE 1200 TONS/DAY 65% FIBRE BOILERS 35% PITH PITH STORAGE TRACTOR TROLLY

  37. UTILISATION OF PITH IN COAL FIRED BOILERS PITH FROM DEPITHERS ADDITIONAL SAVINGS DUE TO BARK 24.08 lacs SAW DUST 8.25 lacs STORAGE PITH B5 INVESTMENT 250 LACS ANNUAL SAVINGS 423.52 LACS B6 B7

  38. REPLACEMENT OF WORM & GEAR ARRANGEMENT BY GEARED MOTORS FOR 42 NOS SURFACE AERATORS SURFACE AERATORS WERE DRIVEN BY 15 Kw MOTORS ALONGWITH REDUCTION GEAR BOXES. REDUCTION WAS THROUGH WORM & PINION ARRANGEMENT WHICH HAD LOW EFFICIENCY. These were replaced by GEARED MOTORS resulting in a savings of 2.96 kw each due to high efficiency. Investment Rs 70.00 lacs Annual savings Rs 21.77 lacs

  39. ENVIRONMENTAL MANAGEMENT • GREEN PRACTISES SYSTEMATICALLY ADOPTED • AND INTEGRATED INTO OVERALL PRODUCTION • PROCESS • ENZYMATIC PRE BLEACHING • BIO REFINING OF PULP • COOKING AIDS IN DIGESTER • FARM FORESTRY • SOLID WASTE MANAGEMENT REQUIREMENT FOR CORPORATE RESPONSIBILITY FOR ENVIRONMENT PROTECTION

  40. WATER CONSUMPTION TREND KL/TON 39.8 kl/t

  41. WATER CONSERVATION ACHIEVED THROUGH 8 MAJOR SCHEMES IMPLEMENTED IN LAST THREE YEARS • RECYCLING OF BLEACHING BACK WATER • RECYLING OF SHEETING M/C BACK WATER • RECIRCULATION OF LIME KILN COOLING WATER • RECLAMATION OF PAPER M/C & STOCK BACK WATER

  42. PROJECTS IDENTIFIED UNDER • CLEAN DEVELOPMENT MECHANISM • PITH FIRED BOILER • DEWATERING PITH PRESS • BURNING OF PH LIQUOR IN BOILERS APPROX CER’S 11000 PA

  43. IMPLEMENTATION OF CORRECTIVE / PREVENTIVE ACTIONS OF ISO - 9000 : 2001 OBSERVATIONS – Analysis of “Customer satisfaction analysis” is not evident for the feed back collected from customers. CORRECTIVE ACTION – Procedure modified to collect attribute wise customer satisfaction data. PREVENTIVE ACTION – Customer Satisfaction data will be collected & analysed

  44. IMPLEMENTATION OF CORRECTIVE / PREVENTIVE ACTIONS OF ISO - 14001 : 2004 OBSERVATION – Review & Revision of environmental aspects is not Evident after completion of Management Programme for EMP-12 (Tar from Producer Gas Plant ) CORRECTIVE ACTION – All Environmental aspects Reviewed. PREVENTIVE ACTION – Procedure for environmental Aspects modified

  45. IMPLEMENTATION OF CORRECTIVE / PREVENTIVE ACTIONS OF OSHAS - 18001 : 1999 OBSERVATION – Mechanism for controlling Sulphuric Acid spillages from one of the sulphuric acid tank is not existing CORRECTIVE ACTION – Dyke wall around the Sulphuric acid tank made. PREVENTIVE ACTION – Review of similar other Tanks which are storing Hazardous Chemicals done

  46. No Type of Waste Material used Quantity of waste material used (T or any other equ Unit) Equiv of Conventional energy used (kWh of electricity or Ton / KL of fuel) Waste fuel as % of total energy 1  Pith  148290 MT 74145 MT coal 13.41 2 Blk Liquor ( solids ) 214897MT 174604 MT coal 32.18 3 PH Liquor (as solids) 6500 MT 7767.5 MT coal  1.43 4 PH Liquor sludge 80.0 MT 71.0 MT coal  0.01 5 DIP sludge 1403 MT 333.3 MT coal 0.06 6 Saw dust 784.3 MT 549.0 MT coal 0.10 7 Wood bark 2402.8 MT 1201.4 MT coal 0.22 47.41 % UTILIZATION OF WASTE

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