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BEST ENERGY SAVING PRACTICES AT BPU. Task Force Program On Energy Conservation (Pulp & Paper Sector) Ballarpur Industries Limited Unit Ballarpur. Energy Conservation In Indian Pulp & Paper Industry. – WHY Energy Conservation ?

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Best energy saving practices at bpu

BEST ENERGY SAVING

PRACTICES

AT BPU

Task Force Program On Energy Conservation

(Pulp & Paper Sector)

Ballarpur Industries Limited

Unit Ballarpur


Best energy saving practices at bpu

Energy Conservation In Indian Pulp & Paper Industry

– WHY Energy Conservation ?

  • Energy Intensive Industry (6th largest Energy Consumer)

  • Increasing Trend of Energy Cost due to fossil fuel depletion (Energy Costs nearly 20% of Mfg. Cost)

  • Far behind in Energy Consumption norms as compared to our competitors in developed countries.

  • Lot of scope in the area of Energy Conservation & hence attractive option for improving profitability & growth.


Best energy saving practices at bpu

Success Story of Unit Ballarpur

Back ground :

Full Fledged Energy Conservation Cell founded in early 1980’s as per VISION of Mr LM Thapar (Chairman, Ballarpur Industries Ltd.).

Objectives :

  • To consider Energy as one of Key and vital Input both on National and Industrial perspective

  • To reduce Energy Cost

  • Energy norms to be made component of Departmental budgets

  • To Reduce energy wastage by regular plant Audits

  • To consider new Energy efficient Technologies and equipment

  • To involve and motivate employees for Energy saving Proposals


Best energy saving practices at bpu

SET UP OF ENERGY CONSERVATION CELL

DEPTT. SUB -TEAMS

CHEMICAL ENGINEER

(HEAD)

MECHANICAL ENGINEER

ELECTRICAL ENGINEER

Group VP

(Op.)

ENERGY

CELL

VP / GM (Tech.)

WEEKLY & MONTHLY AUDIT DATA GENERATION

ENERGY CONSERVATION

MEASURES

(IDENTIFICATION &

IMPLEMENTATION)

ENERGY

AWARENESS

PROGRAMME

DATA

FEED

BACK

CONTROL OF

SAVING ACHIEVED


Best energy saving practices at bpu

PAPER PRODUCTION (Lac MT)


Best energy saving practices at bpu

Energy Cost (% of total Manufacturing Cost)

(In spite of increase in Coal & Grid Power prices)


Best energy saving practices at bpu

Water Consumption (kL/ MT Paper)

Up to

Jan-05


Best energy saving practices at bpu

Specific Thermal Energy Consumption


Best energy saving practices at bpu

Specific Electrical Energy Consumption

* State art of Equipments added in Yr 2002-03 for automation in

Paper cutting & finishing for Improved Quality & Customer Satisfaction


Reasons for increase in power in 2002 03

Increase in Electrical Energy consumption is due to -

- Additional Chlorine Dioxide Production for bleached Pulp.

- Addition of new, automatic paper conversion Equipment

such as Cameron, Pasaban & Wrapmatic.

- Trim Blowers for broke handling at winders.

- Shrink wrap bundling machine

- Modern Paper Warehouse, 5520 Sq. mtr

Reasons for increase in Power in 2002-03


Best energy saving practices at bpu

Specific Energy Consumption


Best energy saving practices at bpu

Paper Finishing New Equipments

Pasaban Cutter 100 TPD

Ream Wrapping Machine


Best energy saving practices at bpu

Paper Finishing New Equipments

New Ware House

Cameron Rewinder

Shrink Bundling Machine


Best energy saving practices at bpu

Best Energy Saving Practices At Ballarpur

Project/ Measures No. 1

Grinding of PM-3 Dryer cylinders

Paper Machine No.3 Dryer cylinders had developed

grooves due to which uniform drying was not taking

place 24nos. Dryer cylinders were grinded by M/S

Pikoteknik Finland for improving Heat transfer &

paper quality which also resulted in reducing the

specific steam consumption.

Steam saving= 1.209 T/hr

= 1.21x 24x 355

= 10309 MT /Yr

Equivalent Coal= 10309 x 0.220

= 2268 MT Coal

Saving in Rs. = 2268 x 1355/-

= 30.73 Lacs

InvestmentRs. 150 Lacs


Best energy saving practices at bpu

Best Energy Saving Practices At Ballarpur

Project/ Measures No. 2 (a)

Increasing moisture by 1.3% after grinding of PM-3 resulting saving Pulp & Steam (for drying).

Fin. Prodn. Nov-03 to Mar-04 = 21080 MT

Increase in moisture (3.5 to 5%)= 1.3%

Saving in fibre (21080x 1.3%)= 274 MT

Cost of pulp Rs/MT= 10500

Saving achieved= 274 x 10500/100000 lacs

Savingin Rs.= 28.77 lacs

Investment: With same investment as in Project No.1


Best energy saving practices at bpu

Best Energy Saving Practices At Ballarpur

Project/ Measures No. 2(b) Reduce the number of steps

Installation of on line QCS on PM-4 for better control of moisture & basis weight. Fiber saving achieved by increasing moisture from 2.54 to 4.4% (1.86%)

Fin. Prodn. Nov-03 to Mar-04 = 4929 MT

Increase in moisture (2.54 to 4.4%)= 1.86%

Saving in fibre (4929 x 1.86%)= 91.67 MT

Cost of pulp Rs/MT= 10500

Cost of Fibre in Rs = 91.68 x 10500/100000

Investment: Rs. 30.40 Lacs


Best energy saving practices at bpu

Best Energy Saving Practices At Ballarpur

Project/ Measures No. 3

Installation of feed water heater in Coal Boiler no. 4 & 6

Feed water heater installed for Coal Boiler no. 4 & 6

to increase feed water temp from 105 to 135 Deg C.

Saving in Coal= 9.315 MT/ Day

= 3260 MT on Yearly basis

Actual Coal saving in the year after installation

= 9.315 x 152days

= 1416 MT

Cost of Coal/ MT = Rs 1355

Saving in Rs. =1416 x 1355/-

= Rs. 19.19 Lacs

Investment Rs. 5.00 Lacs


Best energy saving practices at bpu

Best Energy Saving Practices At Ballarpur

Project/ Measures No. 4

Replacement of old inefficient Cl2 Compressor in CSC plant

Old Cl2 compressor was having less capacity with gland

type design, which has been replaced with higher capacity

new design compressor with mechanical seal. It has

resulted in lower power consumption

Saving in Power = 11.64 x 24 x 330 = 92189

Capturability 95% = 87579 Kwh p.a.

Cost of own generation = Rs. 1.20/ kWH

Saving in Rs. = 1.20 x 87579/ 100000

= 1.05 Lac p.a.

Investment Rs. 3.0 Lacs .


Best energy saving practices at bpu

Best Energy Saving Practices At Ballarpur

Project/ Measures No. 5

Replacement of inefficient rotor of warm water pump in Pulp mill

Presently two pumps of 300 M3/hr with 100 HP x 1450-rpm

motor were running to meet the water requirement in blow

heat recovery running load was 100 & 70 amps respectively.

The total water requirement was 400 to 450 M3/hr. It was

discussed with M & P Engr to replace only rotor (Impeller) to

get the reqd capacity from existing one single pump keeping

casing etc same. The rotor was ordered & replaced in Jan-04,

which is meeting the water requirement with single pump &

running load is 123 Amps

Saving in Power = 30 kwh = 30 x 24 x 350 p.a

= 252000 kwh p.a

Cost of own generation = Rs. 1.20 per kwh

Saving in Rs. = 252000 x 1.20 = 3.02 Lac p.a.

 Investment Rs. 0.75 Lacs for one rotor.


Best energy saving practices at bpu

Best Energy Saving Practices At Ballarpur

Project/ Measures No. 6

Replacement of In-efficient rotor of Warm water pump

Presently two pumps of 300 M3/hr with 100 HP x 1450-rpm motor were running to meet the water requirement in blow heat recovery running load was 100 & 70 amps respectively. The total water requirement was 400 to 450 M3/hr. It was discussed to replace only rotor (Impeller) to

get the reqd. capacity from existing one single pump keeping casing etc same. The rotor was ordered & replaced in Jan-04, which is meeting the water requirement with single pump and running load is 123 Amps

Saving in Power = 252000 kwh p.a. 

Cost of own generation = Rs. 1.20 per kwh

Saving in Rs. = 3.02 Lac p.a.

Investment Rs. 0.75 Lacs for one rotor.


Best energy saving practices at bpu

Best Energy Saving Practices At Ballarpur

Project/ Measures No. 7

Optimising Refiner operations by running 0.5 SDM in place of 0 SDM on PM-6

There are dedicated refiners for PM-4 & 6 having 200 kw & 350 kw motors because of different quality requirements on both M/cs. While in BCP run on PM-6 degree SR requirement is less hence small refiner is being used for PM-6 & resulted in power saving.

 Power saving= 31.23 kwh

Power saving= 266080 kwh p.a

Availability 80%= 212864 kwh p.a

Cost of own generation= Rs. 1.20 / kwh

Saving in Rs.= 2.55 Lacs p.a. Investment: Nil .


Best energy saving practices at bpu

Best Energy Saving Practices At Ballarpur

Project/ Measures No. 8

Reduction in power consumption by reducing Fresh water consumption

Water Consumption in Yr 2002-03 = 20071252

Water Consumption in Yr 2003-04 = 18870131

Saving of water = 1201121 M3

= 12.01 Lac M3 p.a.

Power saved = 886231 kwh p.a.

Cost of own generation = Rs. 1.20 / kwh

Saving in Rs.= 886231 x 1.20 = Rs. 10.6 lacs

Saving in Power = Rs. 10.60 Lac p.a.

(for Pumping from River)

Investment: Rs. 0.25 Lac (No Major Investment)


Best energy saving practices at bpu

Best Energy Saving Practices At Ballarpur

Project/ Measures No. 9

Reduction in Steam distribution Losses.

Improving Insulations & prompt attention on leakages resulted in reducing

the steam distribution losses by 0.34%

Saving in Steam = 4554 MT Steam

Coal / Ton of H P Steam = 209 kgs = 4554 x 0.209

Saving in Coal = 973 MT Coal

Cost of Coal Rs./ MT = 1355/-

Saving in Rs = 973 x 1355 = 13.18 Lacs p.a.

Investment: Rs. 8.00 Lacs on insulation


Best energy saving practices at bpu

Best Energy Saving Practices At Ballarpur

Project/ Measures No. 10

Replacement of 90 nos. conventional tube light fittings with energy saving electronic fittings

Saving in Power = 13 watt per tube

=13 x 90 x 24 350 /1000 kwh p.a.

= 10249 kwh

Cost of own generation = Rs. 1.20 per kwh

Saving in Rs. = 10249 x 1.20 = 0.12 Lac p.a.

Investment: Rs. 0.31 Lacs


Best energy saving practices at bpu

Best Energy Saving Practices At Ballarpur

Project/ Measures No. 11

Optimization of Power factor of MSEB supply to maintain power factor to 0.97 by adding 300 KVAR capacitors.

Resulted savings of Rs 2.4 lacs in Power Bill

Investment Rs. 1.5 Lacs .


Best energy saving practices at bpu

Best Energy Saving Practices At Ballarpur

Project/ Measures No. 12

Repositioning of Vacuum Pump Silencers.

In PM - 6 & 5 pumps were having silencers in discharge

line at the height of 3 Meters due to which water was

being pumped & discharged at height resulting

higher power consumption. These silencers

repositioned at ground level with pump &

resulted in total power saving of 29.25 KWh

Saving in Power = 249210 kwh p.a.

Cost of own generation = Rs. 1.20 / kwh

Saving in Rs . = 249210 x 1.20/ 100000

Savingin Rs. = 2.99 Lac p.a.

 Investment: Rs. 0.50 lacs 


Best energy saving practices at bpu

Best Energy Saving Practices At Ballarpur

Project/ Measures No. 13

Optimization of Operations by running single DDR at PM-3 during Higher GSM

Production 70 & above GSM= 20060 MT

R.Hrs of DDR for above Prodn= 2809 Hrs

Power consumption of DDR /Hr= 242 kw

Power saved = 2809 x 242

= 679778 kwh

Cost of own generation = Rs. 1.20 / kwh

Saving in Rs.= 679778 x 1.2

Saving in Rs.= 8.16 lacs p.a


Best energy saving practices at bpu

Best Energy Saving Practices At Ballarpur

Project/ Measures No. 14 Reduce the number of steps

Utilization of direct heat of blow vapors in Blow heat Recovery

Advantage: Resulted in reduction of steam consumption from 0.850 to 0.788 MT / ton of pulp.

Saving in Coal = 1347 MT p.a.

Cost of coal = Rs. 1355 per MT

Saving in Rs. = Rs. 18.25 Lac p.a.

Investment Rs. 1.8 Lacs for pipe line &

heat exchanger modification.

Implementation :

Successfully implemented with a saving in

coal to the tune of 1347 MT p.a.


Best energy saving practices at bpu

Best Energy Saving Practices At Ballarpur

Project/ Measures No. 15 Reduce Wastes/Losses

Utilization of Flash Steam of PM-6 by providing in-house Condenser

We have installed one old condenser near PM-6, by using its flash steam, hot water is generated & sent to pulp mill for use.

Saving in Coal = 672 MT p.a.

Cost of coal = Rs. 1355 per MT

Saving in Rs. = Rs. 9.10 Lac p.a.

Investment Rs. 0.5 Lacs for pipe line etc.

Implementation : Successfully implemented

with a saving in coal to the tune of 672 MT

p.a.


Best energy saving practices at bpu

Best Energy Saving Practices At Ballarpur

Project/ Measures No. 16 Use Judiciously

Utilization of PP-3 extraction steam in its gland.

3Kg LP extraction steam is being used in place of HP steam thus saving of heat energy difference of both steams.

Saving in Coal = 11.36 MT p.a.

Cost of coal = Rs. 1355 per MT

Saving in Rs. = Rs. 0.15 Lac p.a.

Investment : Nil

Implementation : Implemented successfully

during PP-3 shut.


Best energy saving practices at bpu

Best Energy Saving Practices At Ballarpur

Project/ Measures No. 17 Use Judiciously

Replacing partially RB-1 Air Preheater MP steam with LP Steam (0.632 T/hr) to enhance Power Generation from turbine by 202001 units per annum.

RB-1 primary air Preheater was having three heating coils with MP steam heating. It has been modified by adding one additional heating coil with LP steam & converting one coil from MP to LP steam that has saved MP steam.

Additional power Gen = 202001 units/annum

Saving (@Rs.1,25) = Rs. 2.52 Lacs

Investment Rs. 1.25 Lacs

Implementation :

Successfully implemented during Recovery

boiler shut


Best energy saving practices at bpu

Best Energy Saving Practices At Ballarpur

Project/ Measures No. 18 Correct Sizing is the key

Providing higher size Steam Traps in L & T Heaters to reduce steam loss.

After providing the higher size traps by passing of traps is stopped bypassing resulting in steam saving.

Saving in Coal = 73.85 MT p.a.

Cost of coal = Rs. 1355 per MT

Saving in Rs. = Rs. 1.00 Lac p.a.

Investment Rs. 0.65 Lacs Steam traps & Valves etc.

Implementation :

Successfully implemented with a saving in coal to the tune of 73.85 MT p.a.


Best energy saving practices at bpu

Best Energy Saving Practices At Ballarpur

Project/ Measures No. 19 Cut the Wastes

Installation of thermo pump on PM-6 to lift pre dryer group condensate.

Condensate from PM-6 pre-dryer group was being drained.

One Thermo pump Installed to lift & sent it to

its condensate

Tank.

Saving in Condensate = 4200 MT/annum(50%Capturability)

Cost of condensate = Rs. 30 per MT

Saving in Rs. = Rs. 1.26 Lac p.a.

Investment Rs. 1.60 Lacs for Thermo pump, pipe line

& valves

Implementation :

Successfully implemented with a saving of Rs.1.26 Lacs p.a.


Best energy saving practices at bpu

Best Energy Saving Practices At Ballarpur

Project/ Measures No. 20 Use the location advantages fully

Modification of boiler feed water pump system to save power.

We have increased the head of smaller feed pump (200HP, 55cum/hr & 555mtr head) by using a booster pump of 7.5 kw which enabled to run smaller feed pump with increased head in place of big pump of 350 HP at old feed pump station. There was a reduction of 80 KW in the running load.

Saving in Power = 672000 KWH p.a.

Cost of own generation = Rs. 1.25 per kWH

Saving in Rs. = Rs. 8.40 Lac p.a.

Investment Rs. 1.00 Lacs for pump, pipe line

& valves.

Implementation :

Successfully implemented with a saving in Power 6.72 lac kWH p.a.


Best energy saving practices at bpu

Best Energy Saving Practices At Ballarpur

Project/ Measures No. 21 Harness technical advantages fully

Installation of Variable frequency drive on Decker to save power.

Decker dyno drive has been replaced with

Variable frequency drive resulted in Power saving.

Saving in Power = 13 kW = 13 x 24 x 350 kWH p.a.

Cost of own generation = Rs. 1.25 per kWH

Saving in Rs. = 1.365 Lac p.a.

Investment : Rs.1.65 Lacs

Implementation: Successfully implemented


Best energy saving practices at bpu

Best Energy Saving Practices At Ballarpur

Project/ Measures No. 22 Make use of nearby spare capacities.

Installation of Trim blower for Jagenberg Rewinder to save power.

We have installed one Trim Blower & diverted its trims in

a common Pulper, which has resulted in shutting down

the dedicated Pulper & Achieved Power saving of 46 Kw.

Saving in Power = 391920 kWH p.a.

Cost of own Generation = Rs. 1.25 per kWH

Saving in Rs. =4.89 Lac p.a.

Investment : Rs. 1.65 Lacs for Trim Blower & Pipe.

Implementation : Implemented successfully


Best energy saving practices at bpu

Best Energy Saving Practices At Ballarpur

Project/ Measures No. 23 Use Power Saving Methods

Replacement of tube fittings with power saver electronic chokes.

Approx 70 tube fittings replaced with power saver electronic chokes, which saved

13 watt per tube ie 7972 kWH per annum

Saving in Power = 7972 kWH p.a.

Cost of own Generation = Rs. 1.25 per kWH

Saving in Rs. = 0.10 Lac p.a.

Investment : Rs. 0.25 Lacs

Implementation : This is successfully implemented.


Best energy saving practices at bpu

Best Energy Saving Practices At Ballarpur

Project/ Measures No. 24 Use Power Saving Methods

Replacement of inefficient FD fan of Recovery Boiler No.1

We have replaced Recovery Boiler No.1 FD Fan with Efficient Fan, which has

resulted in power saving of 46 kW.

Saving in Power = 391920 kWH p.a.,

Cost of own Generation = Rs. 1.25 per kWH

Saving in Rs. =4.89 Lacs p.a.

Investment : Rs. 5.00 Lacs

Implementation : This is successfully being

practiced .


Best energy saving practices at bpu

Best Energy Saving Practices At Ballarpur

Project/ Measures No. 25 Reduce the excess weights

Replacement of Cooling tower Aluminum fan No.3 with FRP power saver fan of PP-1 Third Compartment

Power Plant No.1 Cooling tower Aluminum Fan changing into SS Hub & FRP (Hollow) blade construction, there is a reduction in power consumption to the tune of 8 kW.

Saving in Power = 8 kW x 24 Hrs x 360 Days /100000 = 0.691 Lac kWH p.a.

Cost of own generation = Rs. 1.25 per kWH

Saving in Rs. = 0.864 lac p.a.

Investment Rs. 1.00 Lacs

Implementation : Successfully implemented.


Best energy saving practices at bpu

Best Energy Saving Practices At Ballarpur

Project/ Measures No. 26 Integrate Energy and Quality Requirements

Grinding of PM-4 Dryers, addition of one Dryer for increasing the speed & reducing the specific steam consumption

PM-4 Dryer Cylinders were grinded on site by M/s Pikoteknik Finland.

Saving in Steam = 0.348 MT/HR LP steam = 0.333 MT /HR MP steam

= 0.333 x 24 x 360 Days

= 2877 MT Steam

Equivalent Coal = 2877 x 0.211

= 607 MT

Cost of Coal = Rs 1355

Saving in Rs. = 8.22 Lac p.a.

Investment Rs. 100 Lacs for Grinding & related jobs.

Implementation :

Successfully implemented with a saving of Coal by 607 MT.


Best energy saving practices at bpu

PM-4 Dryer Grinding

Grooves Before Grinding

After Grinding

  • Improved Reel Building

  • Improved Paper sheet flatness

  • Paper Moisture increased from 3.5 to 5 %

  • Reduction in steam consumption 0.333 T/Hr


Best energy saving practices at bpu

PM-3 Dryer Grinding

Grooves Before Grinding

After Grinding

  • Improved Reel Building

  • Improved Paper Sheet flatness

  • Paper Moisture increased from 3.5 to 5 %

  • Reduction in Steam consumption from 0.2 to 0.3 T/Hr


Best energy saving practices at bpu

Energy Conservation Completed TQM Projects

  • Reduction in power Consumption by reducing Frequency from 49.8 to 49.6 Hz

  • Reduction in Raw water consumption across the mills

  • IPO Coal Consumption

  • To identify potential area of Steam & power reduction in mills

  • IPO Cooking to reduce Re-blows

  • IPO Steam distribution system to reduce loses

  • Replacement of Inefficient Cl2 Compressor


Best energy saving practices at bpu

IPO Water supply to Evaporators surface condenser by shutting one pump

IPO Vacuum pumps in paper M/C area to reduce power consumption

IPO Power Generation to reduce steam for power

Study of Pumps Efficiency consuming power >100 Kw

TQM Projects Under Progress


Best energy saving practices at bpu

Unit: Ballarpur has Won

First Prize

In Industrial Sector of Maharashtra

For

Excellence in Energy Conservation & Management

2003


Best energy saving practices at bpu

We are Committedto Conserve Energyby Motivating Our Peoplefor Optimal Use of TechnologyandNatural Resourcesat an Affordable Cost


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