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CENTURY PULP AND PAPER LALKUA, NAINITAL ( A BK BIRLA GROUP OF COMPANY ) PowerPoint PPT Presentation


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CENTURY PULP AND PAPER LALKUA, NAINITAL ( A BK BIRLA GROUP OF COMPANY ) ISO –9001 – 2000 AND ISO -14001 CERTIFIED COM PANY . AN INTEGERATED PULP & PAPER UNIT 31320 TPA RAYON GRADE UNIT

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CENTURY PULP AND PAPER LALKUA, NAINITAL ( A BK BIRLA GROUP OF COMPANY )

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CENTURY PULP AND PAPER

LALKUA, NAINITAL

( A BK BIRLA GROUP OF COMPANY )

ISO –9001 – 2000 AND ISO -14001 CERTIFIED COM PANY

  • AN INTEGERATED PULP & PAPER UNIT

  • 31320 TPA RAYON GRADE UNIT

  • 37250 TPA WOOD BASE WRITING PAPER

  • 84600 TPA BAGASSE BASE PAPER

ECO MARKED

BAGASSE PAPER


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CENTURY PULP AND PAPER

POWER ARRANGEMENTS

  • 6.8 MW TG SET

  • 21 MW TG SET

  • 7.5 MVA CONTRACT DEMAND FROM

  • UPCL

6,10,000 UNITS /DAY


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CENTURY PULP AND PAPER

THERMAL ENERGY ARRANGEMENTS

23 TPH 46 Kg/cm2FBC C F B 3 NO

25 TPH 46 Kg/cm2 SPREADER STOCKER CFB 1 NO

50 TPH 62 Kg/cm2 FBC C F B 2 NO

40 TPH 46Kg/cm2 CHEM REC BOILER( BHEL ) 1 NO

50 TPH 62Kg/cm2 CHEM REC BOILER( ABL ) 1 NO


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ELECTRICAL ENERGY (KWH) : 2001 - 2004


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  • ELECTRICITY CONSUMPTION AND COST

  • 2001-02 2002-03 2003-04

  • PURCHASED

  • UNITS (Lac kwh/yr) 239.83 192.27 159.73

  • COST ( Rs lacs/yr) 1399 1177.84 746.84

  • OWN GENERATION

  • THROUGH DG SETS

  • UNITS (Lac kwh/yr) 47 34.81 19.37

  • COST ( Rs lacs/yr ) 219.44 182.88 117.13

  • THROUGH STEAM TURBINES

  • UNITS ( Lac kwh/yr) 1754.58 1865.88 2001.13

  • COST ( Rs lacs/yr) 1937.58 1974.96 1903.86


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TOTAL CONSUMPTION OF ELECTRICITY

2001-02 2002-03 2003-04

UNITS (Lac kwh/yr ) 2041.41 2092.96 2180.23

COST (Rs lac/yr) 3556.02 3335.68 2767.83


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  • THERMAL ENERGY CONSUMPTION FOR PROCESS

  • 2001-02 2002-03 2003-04

  • COAL

  • HEAT VALUE (Mkcal/yr) 728037 653007.6 651336.7

  • BLACK LIQUOR

  • HEAT VALUE 659445 704815 711616.75

  • PITH

  • HEAT VALUE 60501 78867 74641.5

  • TOTAL 1447983 1436690 1437595


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  • 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


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ASSESSMENT & MONITORING

  • AUDIT CONDUCTED BY CII : APRIL2003

  • 39 ENERGY SAVING SCHEMES IDENTIFIED

  • AUDIT CONDUCTED BY INGERSOLL RAND : SEPT 2003

  • 8 SCHEMES IDENTIFIED

  • AUDIT CONDUCTED BY ECKO PUMPS FOR PAPER

  • M/C III VACUUM SYSTEM : OCT2004

  • 4 SCHEMES IDENTIFIED

  • AUDIT CONDUCTED BY DSCL FOR ENERGY COST

  • REDUCTION IN FEB 2004 : 4 SCHEMES IDENTIFIED

  • MOTOR EFFICIENCY ASSESSMENT BY VBI SYSTEMS

  • PLANT TECHNICAL AUDITS BY INDEPENDENT

  • COUNSULTANTS : AUG 2004


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ORGANISATIONAL SET UP FOR ENERGY CONSERVATION

PRESIDENT

EC CELL

LOSS IDN COM

ISO 14001/

ISO 9001/QC

TPM

* PRODUCTION * TPM SEC * 3 MEMBERS * MR.

* POWER HOUSE * PILAARS * CROSS FUNCT * SYSTEM COORD.

TEAMS

* ELECT&INST * OVERLAPPING * QUALITY CIRC

COMMITTEES

* ENV & WATER

* STO & PUR

* PURTA


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  • 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


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TPM

A ZERO BASED

APPROACH

ENHANCE PLANT

EFFICIENCY


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ZERO BASED APPROACH

LOSS

FAILURE

DEFECT

DOUBT

ACCIDENT

BREAKDOWN

0


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AUTONOMOUS MAINTENANCE( JISHU HOZEN )

MY MACHINE

I MAINTAIN


Education and training

EDUCATION AND TRAINING

  • SKILL DEVELOPMENT : TRAINING PROGRAMME

    • TPM AWARENESS 118

    • TECHNICAL 722

    • BEHAVIORAL 99

    • FIRE AND SAFETY 209

  • ON JOB TRAINING THROUGH

    ONE-POINT-LESSON SHEET


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TPM RE- DEFINED

TOTAL POSITIVE MIND

TOTAL POSITIVE MIND

TOTAL POSITIVE MIND


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  • LOSS IDENTIFICATION COMMITTEE

  • HIGHLIGHT PROCESS INEFFICIENCIES

  • CHECK LOSSES OF ALKALI,FIBRE,WATER,

    CHEMICAL AND STEAM

  • ARRANGE CORRECTIVE MEASURES


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  • 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


Annual saving in power utilisation without investment

ONLY MENTAL ENERGY

ANNUAL SAVING IN POWER UTILISATIONWITHOUT INVESTMENT


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NO / LOW INVESTMENT SCHEME

2001-02 2002-03 2003-04

NO OF SCHEMES 2 8 9

SAVINGS / ANNUM

KWH (LACS) 11.82 8.914 36.755

COAL EQ (TONS) - 16366 32550

Rs ( LACS) 24.65 312.45 658.64

INVESTMENT 2.11 - -

TOTAL

Rs 995.74


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ENERGY CONSERVATION SCHEMES

NO / LOW INVESTMENT

( 2001 – 02)


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ENERGY CONSERVATION SCHEMES

NO / LOW INVESTMENT ( 2002 – 03)


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NO / LOW INVESTMENT ( 2002 – 03)


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NO / LOW INVESTMENT ( 2002 – 03)


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NO / LOW INVESTMENT ( 2003 – 04)


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VARIABLE FREQUENCY DRIVES


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  • ENERGY CONSERVATION SCHEMES

  • VFD2001-02 2002- 03 2003-04

    TOTAL NOS INSTALLED 16 11 25

  • INVESTMENT 39.3 8.06 31.03

  • SAVINGS /ANNUM

  • KWH (LACS) 21.2 3.66 11.36

  • Rs (LACS) 42.4 8.22 22.72

73 . 34 LACS

UNIT COST Rs 2.00


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VFD - FANS, BLOWERS & PUMPS

AFFINITY LAWS

Q1 = N1

Q2 N2

2

P1 = N1

P2 N2

3

HP1 = N1

HP2 N2

P2

P

mtr of

wc

P1

Q1

Q2

Q(LPM)


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THROTTLING VS SPEED CONTROL


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POWER REQUIREMENT

VSD VS VALVE THROTTLING

  • A- damper control =

  • 0.4 +0.6Q

  • B -VSD control = Q3

  • ASSUMPTIONS :

  • Static Head on fan/

  • pump is negligible.

  • Fan/pump input is 0.4

  • Per Unit under full

  • valve/ damper

  • closed condition.

100

A

Fan/

Pump

Input

Power

80

60

40

20

B

.2 .4 .6 .8 1.0

Q(LPM)

Per unit flow discharge


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ENERGY CONSERVATION SCHEMES

ELECTRICAL VFD (2001-02)


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ELECTRICAL VFD (2002-03)


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ELECTRICAL VFD (2003-04)


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ELECTRICAL VFD (2003-04)


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SLD BAGASSE PAPER M/C


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SLD BAGASSE PULP


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SLD RGP MCS


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SLD WPP CCS

ETP TR 3


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132/11 KV

10MVA

11/11KV

TG 2

21 MW

TG 1

6.8MW

BPULP

B M/C

RGP

WPP


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HARMONICS STUDY FINDINGS

TG1 TG2 DG GR TR 1 GR TR 2

Vthd 1.93 3.80 2.98 0.72 1.78

Ithd 3.52 3.63 3.42 1.17 1.78

PERMITTED VALUES 5 %


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  • OTHER ELECTRICAL SCHEMES FOLLOWED:

  • 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

      COMPLETE GROUP EQUIPMENTS OF PLANT

    • SWITCH OFF EQUIPMENTS THROUGH TIMERS

  • 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


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TOTAL SAVINGS / ANNUM

( FOR LAST THREE YEARS)

KWH (LACS) 4.62

Rs (LACS) 9.24

INVESTMENT Rs (LACS) 9.65


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ENERGY CONSERVATION SCHEMES

ELECTRICAL OTHERS


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ENERGY CONSERVATION SCHEMES

ELECTRICAL OTHERS


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TOTAL SAVINGS

THERMAL / PROCESS 2001-02 2002-03 2003-04

INVESTMENT 77.55 78.90 853.79

SAVINGS

KWH (LACS) 29.02 27.69 19.73

COAL EQ.(TONS) 6765.7 5500 3593

Rs (LACS) 235.48 160.58 574.46

970.52

KWH = Rs 2.00

COAL/TON = Rs1800


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ENERGY CONSERVATION SCHEMES

THERMAL / PROCESS 2001 - 02


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THERMAL / PROCESS 2001 – 02 contd…


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THERMAL / PROCESS 2002 – 03 contd…


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THERMAL / PROCESS 2003 – 04


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THERMAL / PROCESS 2003 – 04 contd…


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1888.53

  • TOTAL ENERGY SAVINGS FOR

  • LAST 3 YEARS

  • 2001- 02 2002- 03 2003- 04

  • NO OF MEASURES 8 34 47

  • ( IMPLEMENTED )

  • INVESTMENT (LACS) 77.85 138.8 893.85

  • SAVINGS ACCHIEVED

  • KWH (LACS) 38.94 66.27 78.614

  • THERMAL (FUEL ) 11063 87900 143608

    ( MkCAL )

  • Rs LACS 205.61 541.17 1141.75


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RGP 44

PAPER 92

SPECIFIC POWER

CONSUMPTION TREND


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RGP 1.468

PAPER 1.346

SPECIFIC STEAM CONSUMPTION

Mkcal / TON


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  • INNOVATIVE SCHEMES

  • SUBSTITUTION OF FURNACE OIL

  • UTILIZATION OF SOLID WASTE

  • OPTIMIZATION OF GENERATION


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ENERGY THROUGH

RFO HIGH COST FUEL

PRODUCER GAS PLANT

RECALCINE

LIME

LIME SLUDGE


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ENERGY THROUGH

COAL - LOW COST FUEL

PRODUCER GAS PLANT

RECALCINE

LIME

LIME SLUDGE

INVESTMENT Rs 338.0 LACS

SAVINGS IN2003-04 Rs 196.0 LACS


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BAGASSE STORAGE


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DE - WATERING PITH PRESS

CONTINUOUS

DIGESTER

WASHING

BAGASSE

WET PITH

80 % MOISTURE


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DE - WATERING PITH PRESS

BAGASSE

WASHING

CONTINUOUS

DIGESTER

INVESTMENT : Rs 348.29 LACS

ANNUAL SAVINGS : Rs 134 LACS

DE – WATERING

PITH PRESS

50 % MOISTURE PITH


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OPTIMIZATION OF GENERATION

POWER GENERATION 23.5 MW

130.6

70.65

B1

B4

BH

EL

B5

B6

A

BL

15.0

62

46

PRDS

110.5

68.94

21 MW

6.8MW

PRDS

27.28

PRDS

COND

33.17

80.75

4.7

3.5

3.5

15.8

37.41

2.5

PLANT

10.5

10.5

PLANT

PLANT

PLANT


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OPTIMIZATION OF GENERATION

POWER GENERATION 22.0 MW

133.4

50.6

B1

B4

BH

EL

B5

B6

A

BL

20.27

46

62

PRDS

111.2

68.94

21 MW

6.8MW

PRDS

23

PRDS

COND

33.42

73.43

3.36

3.5

3.5

2.0

14.71

35.52

PLANT

10.5

10.5

PLANT

PLANT

PLANT


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OPTIMIZATION OF GENERATION

  • SAVINGS

  • FULL EXTRACTION AT 10.5 Kg/cm2 REDUCED PRDS FLOW

  • HIGHER STEAM FOR COGEN IMPROVED EFFICIENCY

  • REDUCED VENTING OF STEAM

  • STOPPED ONE CFB

  • DEARATOR STEAM REDUCED

  • ONE BOILER FEED PUMP STOPPED

  • LOAD ON COOLING TOWER REDUCED

  • COAL @2700MT/MONTH Rs 583 LACS

  • POWER @350 KWH Rs 56 LACS

  • TOTAL Rs 639 LACS


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  • ENVIRONMENTAL MANAGEMENT

  • GREEN PRACTISES SYSTEMATICALLY ADOPTED

  • AND INTEGRATED INTO OVERALL PRODUCTION

  • PROCESS

  • ENZYMATIC PRE BLEACHING

  • BIO REFINING OF PULP

  • COOKING AIDS IN DIGESTER

  • FARM FORESTERY

  • CONSERVATION OF RESOURSES

  • SOLID WASTE MANAGEMENT

REQUIREMENT FOR CORPORATE RESPONSIBILITY

FOR ENVIRONMENT

PROTECTION


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WATER CONSUMPTION TREND

KL/TON

24


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WATER CONSERVATION ACHIEVED

THROUGH 23 SCHEMES IMPLEMENTED IN

LAST THREE YEARS

  • RECYCLING OF BLEACHING BACK WATER

  • RECYLING OF SHEETING M/C BACK WATER

  • RECIRCULATION OF COOLING WATER

  • RECLAMATION OF PAPER M/C & STOCK

    BACK WATER


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CHLORINE CONSUMPTION

KG/TON

24


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Energy Conservation

Projects ( Planned )

Anticipated Savings in

Approx inv

(Rs lakhs )

Project Commencement&

Completion year

Energy Value

Rs Lakhs

Modify single step control to Dual Control in all Air compressors

1.96 lacs kwh per annum

3.87

3.6

2004 - 05

Installation of air saving Nozzles for blowing and cleaning operations

0.25 lacs kwh per annum

0.5

0.4

2004 - 05

Use of blower in place of compressed air for removal of Paper crease

2.3 lacs

Kwh per annum

4.67

2.5

2004 - 05

Replace existing HOC Air Drier by Refrigeration Type and installation of zero loss drain traps along withReservoirs

3.74 lacs kwh per annum

7.48

24.73

2004 - 05

At A4 Cutter conversion of 8*7 ESV Air end to 9*7

0.86 lacs kwh per annum

1.72

2.00

2004 - 05

FUTURE PLANS


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Excess air control in Coal Fired Boilers by installation of O2 Analyzer and Modifications in automation

866 ton coal

per annum

15.5

32

2004 - 05

Excess Air Control in Chemical recovery Boilers

650 ton coal

per annum

24

-

2004 - 05

Replacement of Fluid Coupling by VFD for Chemical Recovery Boilers

3.5 lacs kwh

per annum

8

12

Being evaluated

Installation of VFD for Boiler Feed Pump

9.5 lacs kwh per annum

19

14

2004 - 05

Installation of VFD for B5 & B6 PA Fans

3.5 lacs kwh per annum

7

4

2004 - 05

FUTURE PLANS CONTD….


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Substitute the existing reciprocating Compressors by installation of Centrifugal Compressor with Heat Recovery System

32 lacs kwh per annum

64.35

135

Being Evaluated

Replacement of frequent rewound low Efficiency motors by Level1 motors

6.9 lacs kwh per annum

13.85

21.85

2004-05

VFD for Identified variable flow requirement in process

8.0 lacs kwh per annum

16.0

20.0

2004-05

FUTURE PLANS CONTD….

SCHEMES WITH AN INVESTMENT OF Rs 125.08 LACS AND SAVINGS OF Rs 113.59 LACS


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SCHEMES IN HAND

INSTALLATION OF WASTE FIRED BOILER 2000 LACS

INSTALLATION OF BLACK LIQ CLARIFIER 120 LACS

RETROFITTING OF LIME KILN 374 LACS

AUTOMATION OF PULP MILLS BY DCS 300 LACS


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  • AWARDS & RECOGNITIONS

  • SELECTED AS A MODEL UNIT BY CPCB/NPC FOR

    WASTE MINIMIZATION

  • AWARDED CERTIFICATE OF APPRECIATION

    FOR ADOPTING CLEANER PRODUCTION

    TECHNOLOGY UNDER UNEP

  • ECO MARK FOR BAGASSE BASE PAPER BY

    BUREAU OF INDIAN STANDARDS

  • GREENTECH INDO GERMAN AWARD FOR

    ENVIRONMENTAL EXCELLENCE : 2002

  • BEST ENERGY CONSERVATION AWARD BY

    INDIAN PAPER MANUFACTURERS

    ASSOCIATION : 2003 AND 2004

  • AWARDED ENERGY EFFICIENT UNIT FOR 2004 BY CII

  • AWARDED FIRST PRIZE FOR ENERGY CONSERVATION

    FOR 2004 BY MINISTRY OF POWER


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THANKS


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