19th CII NATIONAL AWARD FOR “ EXCELLENCE IN ENERGY ...

19th CII NATIONAL AWARD FOR

“ EXCELLENCE IN ENERGY MANAGEMENT-2018”29 -31st AUG 2018

CENTURY PULP & PAPER

LALKUA

Presented By: Anil Setia (Head Engineering)

Arpan Gupta (Asst Manager)

CENTURY PULP & PAPEREstablished in 1984 with 20000 TPA

Rayon Grade Pulp & Timber Based Paper

1984

• PM 1 & 2 MECHANO 110 TPD

1995

• PM 3 VOITH-SULZER 250 TPD

2007

• PM 4 VOITH-SULZER 250 TPD

2009

• PM 5 METSO 100 TPD (TISSUE )

2012

• BM 6 VOITH 500 TPD (BOARD)

3

Machine Capacity Enhancements

over the years , Milestone….

Installed Capacity- 4.53Lac Ton

Production: 1280Ton/day

Power Source

Turbo Generator I

6.8MW

Turbo Generator II

21MW

Turbo Generator III

16MW

Turbo Generator IV

43MW

UPCL Contract Demand

11MVA

Thermal Energy Arrangements

Coal Fired Boilers

Boiler no-5 50Ton/Hr, 62

kg/cm2


kg/cm2

Boiler no-9 100Ton/Hr, 62 kg/cm2

Renewable Boilers

BHEL 40Ton/Hr, 46

kg/cm2

ABL 50Ton/Hr, 62

kg/cm2

ENMAS 178Ton/Hr,62

kg/cm2

Waste/Coal Fired

Boilers


kg/cm2

Boiler no-8 100Ton/Hr, 62 kg/cm2

Energy Generation Trend (2017-18)

TURBINE 6.80MW

0%

TURBINE 21.00MW

22%

TURBINE 16.00MW

17%

TURBINE 43.00MW

57%

DG Set0%

UPCL POWER

4%

Power Generation Trend

Coal/Pith Boiler62%

Recovery Boiler38%

Steam Generation Trend

Bagasse

Surge Chest

Bleached Pulp

From Pulp Mill

Blend Chest

Softwood

pulp

OBA

Talcum

Dye

Machine Chest

Cleaners

Screening

To

PM/C

S.R.Box

Process Flow Diagram (Stock-PM#3)

Wire part

Head

Box

Press

Film

PressCalendar

Paper

Roll

Dryers

Process Flow Diagram (PM#3)

9.30

8.77

8.31 8.23

2014-15 2015-16 2016-17 2017-18

1368.55

1294.86

1212.001183.00

2014-15 2015-16 2016-17 2017-18

Parameters 2014 - 2015 2015 - 2016 2016- 2017 2017-18

Specific Electrical Energy Consumption

(kWh/MT of FNP)

kWh/MT of

FNP1368.55 1294.86 1212.00 1183.00

Specific Thermal Energy Consumption

(MT Steam/MT of FNP) with condensing

MT Steam/MT

of FNP9.30 8.77 8.31 8.23


(MT Steam/MT of FNP) with out

condensing

MT Steam/MT

of FNP7.55 6.99 6.59 6.53

Reduction in Specific Energy Consumption

Specific Electrical Energy

Consumption (kWh/MT of FNP)


(MT Steam/MT of FNP)

12% reduction 14% reduction

Including Condensing steam

7.55

6.99

6.59 6.53

2014-15 2015-16 2016-17 2017-18

13% reduction

Excluding Condensing steam

4140

39

37.5

34

36

38

40

42

2014 - 2015 2015 - 2016 2016-2017 2017-18

SEC- Water Consumption(M3 /MT of FNP)

M3\MT

Parameters 2014 – 2015 2015 - 2016 2016 - 2017 2017-18

Specific Water Consumption (M3/MT of FNP)M3/MT

of FNP 41 40 39 37.5

Specific Water Consumption

• Scheme implemented – 14 No

• Saving of water – 414 M3\Hr

9 % Reduction

Project List

PAT Cycle Status (PNP004UK)

ESCerts issued : 26414No.

0.5910.568

0.466

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

NotifiedBaseline SEC

NotifiedTarget SEC

Normalizedachieved SEC

Toe/Ton

0.7770.738

0.657

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

NotifiedBaseline SEC

NotifiedTarget SEC

SECAchieved(2017-18)

Toe/Ton

PAT Cycle-I PAT Cycle-II

Final year for PAT-II is 2018-19

21% reduction15.44 % reduction

Comparison with Global/National Bench Mark

Century Pulp & Paper is a unique plant which makes no. of qualities with different type

of raw material.

We found some benchmark for SEC from earlier CII energy awards.

However we set our own target for FY 18-19 & continuously improving our efficiency

in comparison of last years (Refer our earlier slide):

Thermal SEC with condensing

steam- 8.23 MT of steam /MT of FNP

S.No. ParticularsPower

(KWh/T)Steam (T/T)

Water (M3/T)

Source

1 Global 1200 5.1 25Industrial Efficiency

Technology Data Base

2 National 1300 6.5 40 CPPRI

3 CPP 1183 6.53 37.5

1183

10901030

980 950

700

900

1100

1300

2017-18 Year-1 Year-2 Year-3 Year-4

8.238.06

7.81

7.57.25

6.5

7

7.5

8

8.5


6.536.30

6.005.80

5.60

5

5.5

6

6.5

7


Including Condensing steam (T/T)

Excluding Condensing steam T/TKWH/Ton

Road Map to achieve Excellence in EE:

Increase in production capacity- 1.5 Lac tons p.a.

(5year plan);

•Tissue-300 TPD

•Board Machine

•PM3 & 4 Up gradation

•Recovery Island Capacity enhancement

•Centralize refining

•PGP Enhancement

•Steam Condensate

•Vacuum Pump Optimization

Project List

To Achieve best Electrical SEC in industry

we are working on the following Points:

•Line Loss Reduction

•New VFD Installation

•LED Light Installation

•Solar Plant (5 MW)

•Energy Efficient Motors & Pumps

• Ideal running stoppage

•PM3 Drive up gradation (DC to AC)-

Present SEC 170KWH/MT proposed

<120KWH/MT

To Achieve best thermal SEC in

industry we are working on the

following Points:

•Insulation

•Black liquor dilution Control

•Uncontrolled heating

•Dead Load Control

•Steam Trap Optimization

•Condensate recovery

•Moisture control on final product

•Heat Exchangers & Filters

Road Map to achieve Excellence in EE:

Project List

Approach for Energy Conservation

Thermal

Steam Trap/Insulation

Steam & Condensate

Waste heat Recovery

Temp Loops

Compressor Automation

Operation Philosophy

Electrical

Line Loss

(Voltage Optimization, PF correction)

VFD’s

Lightning Energy

Power Quality Improvement

(AHF)

Energy Efficient Motor

Waste Utilization

Bio-Gas

CMG-Gas

Pith

Saw-Dust

Bark

System Improvement

Steam Leakages

Air Leakages

Roller Maint.

Water leakages

Mechanical seal

External Support

Audit by M/S Kadant

Vendor Development

Boiler Audit by M/S Venus

Energy

Process Improvement audit by ABB

157

53 5747

0

40

80

120

160

200

Total projects zeroInvestment

investmentupto 2 lacs

investmentabove 2 lacs

No of project

Energy Conservation Projects (Electrical) 2015-18

Project List

Saving

870.37

Lacs

Saving

327.15

Lacs

Saving

1520.71

Lacs

36

8 9

19

0

10

20

30

40

Total projects zero Investment investment upto5 lacs

investmentabove 5 lacs

No of project

Energy Conservation Projects (Thermal) 2015-18

Project List

Saving

1779.59

Lacs

Saving

1367.81

Lacs

Saving

1893.46

Lacs

Summary of Savings- Year Wise

2015-16 2016-17 2017-18

Elect Thermal Total Elect Thermal Total Elect Thermal Total

No of projects 63 7 70 29 15 44 65 14 79

Saving (Rs in Cr) 9.17 24.3 33.47 9.01 12.81 21.82 8.99 14.14 23.13

Zero invest Saving(%)

42.75 27.16 31.43 29.30 3.36 14.07 24.47 56.58 44.13

Major energy conservation Initiatives (2015-16 & 2016-17)

2015-16

• Fuel replacement: By using CMG in place of LPG-3080kg/day

• Turbo Blowers for Air Circulation in Aeration Tank-150KW saving

• Fiberline-Heat Recovery From Effluent- reduction of 1.36T/hr live steam

• Boiler Optimization-12T/hr more steam generation & 550KWh Aux power saving.

• Technology up gradation- IR Compressor, vacuum pump & LC Pump-Saving of 335KW

• Increase in generation of 2MW at 21MW TG

• PM 1 Steam condensate-8640T steam saving p.a.

• O2 CO analyzer-Increase in steam Generation 9Ton/Hr

• Installed o2/co on line measurement system

2016-17• Optimization of BFW Pump-610KW Saving

• PM 2 Steam condensate-8640T steam saving pa

• Evaporator 3 PLFT product temp control -0.5 MT/ Hr saving

• Causticising Plant : Temperature control at Hot water tank -Steam Saving of 12 MT/day.

• VFD on MC pumps (Fiber Line) in place of control valve- saving of 259KW

• Fiber Line: Opti-batch Adoption- production enhancement & energy saving

• Power House:- PRDS Reduction 18 Bars –additional power of 60KWH

• Increase in TG power generation(16MW TG) by 1.23MW- coal saving 1.2T/Hr

POWER QUALITY IMPROVEMENT

•INSTALLATION OF AHF ON TRFO NO

# 704 & 710

Saving of 58 KW i.e. Rs 13.78 Lacs

Adv: Reduce distortion of the normal

electrical current waveform, transmitted

by nonlinear loads

Future Planning: Power supply of DCS system

to be connected through AHF (To avoid DCS

card failure)

Major Energy Conservation Project-1 (2017-18):

INSTALLATION OF AHF (Board Plant)

Advantage: •150 KW/15.65 Ton steam saving.

•Better steam Power balancing.

•Flexibility in online load shifting..

Efficiency gain at TG

Before: • At Low Load, Increased temp of 2nd

extraction (Less Thermal Expansion)

causing less generation

•Less enthalpy drop in 43MW TG

After :

•Transfer 2MW load on 43 MW TG.•Due to increase in load at 43MW, 2nd stage

expansion improved

•Extraction Temp drop by 3-4 0C i.e. extra

generation of 1.5KWH/ Ton of extraction

steam


PA Fan for Boiler No-8 & 9 :

Before: •To Full Fill the Primary air requirement, PA

Fan was running with its standby

equipment in Parallel operation.

•High power consumption .

•Less plant reliability due to non-availability

of stand-by Fan.

After :•Installed new Higher capacity Fan which

will run independently

•Other Fan (existing) will serve as Stand-by

Advantage: •75 KW saving

•System reliability increase by

adding them as stand-by


Optimization of Circulation

pumps -16 MW Cooling Tower:

Before: • 2 No pumps was running on full rpm while

head & flow requirement was less.

•1 no pump was standby

• High power consumption .

• Vacuum Maintained at 0.95mmWC

After :•Trial taken by throttling the valve & optimize

the flow & head by maintaining the Vacuum of

0.95mmW C.

•After Successfully trial 1 pump converted from

DOL to VFD and remaining 2 kept same

•Optimize the rpm from 1000rpm to 650 rpm

Advantage: •Average saving of 112KW.


Enmas Recovery Boiler Soot

Blowing Sequence:

Before: • Earlier Soot blower done in zig-zag &

vertical sequence

•Steam temp was less than 435 0C

•Power house facing problem with steam

temp.

•Less Generation

After :•Monitored the steam temp according to soot

blower sequence & where we get the temp

gain (Specially at inlet & outlet of boiler bank),

we increased the effectiveness of soot blowing

by changing its sequence/repeatation.

•Pressure/Flow optimization at furnace soot

blower.Advantage:

• Steam temperature increased from 435 0C to 445 0C.

•Saving of 37KJ/T of steam generate


Evap-3 Washing Sequence

Change:

Before: • Earlier at finishers washing done through

Condensate and taken in WBL system for

reprocessing

•Resulted higher steam consumption.

After :•Now washing done through Weak black liquor

(WBL)

•No dilution

•Resulted increase in inlet Solid

Advantage:

• 41 Ton/day steam saved

• Condensate saved.

• Evaporator efficiency improvement


LED Light (Mill & Colony) :

S.No Description Quantity (No)

1 High Mask- 200Watt 120

2 Tube light (1*18) 600

3 Tube light (2*18) 2100

4 LED Light 150 Watt 235




Use of tertiary treated water for dust control at

power house by installation of 168 no water

sprinklers :

Before:

Fresh water was being used for dust

control at Power house coal storage &

handling area.

After :

Tertiary treated water is being

utilized.

Advantage:

Reduction in water consumption by 1000

m3 per day.

Major water Conservation Project-8 (2017-18):

Steam Flow control with limit function to prevent transient high Steam flow

Innovation Project-1:

• Low Boiler Efficiency (82%)

Problem

• Maintain const Bed Temp (930 Deg)

• Maintain Const Feed & Air

Objective•Consistence regulation of Boiler fuel

•Compartment Slum as per Plant demand

Challenges

• High Peak Steam Demand 480 to 500 T/Hr against avgdemand of 430T/Hr

Constraint

• Peak demand of Digesters at Pulp Mills

Reason

Source of Idea: Boilers inefficiency due to steam demand peaks of digester

Process conditions: With the inherent nature of Digester batch process, the steam flow

consumption increased to more than 32TPH from 20TPH within span of 2 minutes. This hampered

Boiler and TG operation and sudden surge in fuel consumption with related process upsets

Problem Encounter

Power Block Combined Cycle Eff. Improvement

(Peak Demand control in FL Digester):


• Digester Cooking Cycle

Study

• Steam peak of 35 Ton with in a Spam of 2 Minutes for at least 12-15 Cycles a day

Finding•Peak Demand 35T/Hr locked to 80% with out affecting cooking cycle & Cuppa No

Innovation

• Peak Steam Demand controlled

Result

• Boiler Efficiency improved (0.25%)-1200T Coal saved

• Steam saving 0.05T /TPulpi.e 6262Tons

Saving

How we did it

Before After

Replication: RGP, WPP & Bag Pulp Mill


Adaptation of API plan 54 inplace of API Plan 32 in Pumps Mechanical

seals (Pulp Mill -Cooking & washing Area) :

Potential:

•Avoid water mixing in WBL.

•Steam Saving at Evaporator (due to non mixing of water in WBL)- 6240Ton p.a.

•All Pulp Mill Cooking & washing Section

Source of Idea: Low Solids volume in WBL due to excess water from pulp mill

Innovation: Adaptation of Double Mech Seal with API plan 54 (Design Changed)

Innovation Project-2:Saving From Mechanical Seal Water Leakage

i) Water Outlet flow from mechanical seal - 5LPM

ii) Water Outlet flow from mechanical seal in M3/Hr.- 0.3m3/Hr.

iii) Total outlet water from mechanical seal in per Year- 2400m3

iv) Total steam consumption for evaporation of water- 480Ton

v)Total cost of steam for evaporation of water

605760INR

Total Saving:

13 No Mechanical Seal upgraded in Fiber Line i.e. saving of Rs 79 Lacs

Replication: MC/LC Pump of RGP, WPP & Bag

Pulp Mill

Installation of Auto Tube Cleaning System & Optimization of VAM


How we did it

•Installation of Auto Tube Cleaning System

Benefits :

•Reduction in chilled water temp by 7-8°C from

23°C .

•Steam consumption decrease by approx

150Kg/Hr.

•Achieved capacity of 300TR & maintaining drive

room temp.

• No shut down required.

Problem Encounter:

•High Chilled water & cooling water Temp

•Frequent tripping of drive system & card failure

due to high Temp

•Manual cleaning of scaling - No Shut available

due to continuous Running.

•Higher steam consumption1350 kg/hr

Source of Idea: CII Award Function

Replication: VAM of Clo2 & Fiberline

2015 - 2016 2016- 2017 2017- 2018

Waste

Fuel as %

of total

energy

used

Name of the

Fuel

Quantity of

waste Fuel

used

Heat Value

(million

kcal/year)

Name of the

Fuel

Quantity of

waste Fuel

used

Heat Value

(million

kcal/year)

Name of

the Fuel

Quantity of

waste Fuel

used

Heat Value

(million

kcal/year)

Pith/waste 123909 210645.3 Pith/waste 110972 188652.4 Pith/waste 98452 167368.4 5.40

Black Liquor 425368.79 1382448.5 Black Liquor 385206 1251919.5Black

Liquor401418 1304608.4 37.53

Utilization of renewable energy

sources(alternative fuel utilization)

2 dedicated turbine i.e. 21MW TG & 6.8MW for

using waste heat recovery through 3 no. Recovery

Boilers.

Fuel used is Black Liquor which is a declared Bio-

mass product from MNRE.

Waste Utilization by converting Bagasse effluent

into Bio-Gas/CMG

Pith5%

Black Liquor38%Coal

54%

FO3%

Pith

Black Liquor

Coal

FO

• Wood dust, Pith & bark used in Pith Boiler for steam generation.

• Fly ash utilization for manufacturing of Fly Ash Bricks & Cement through

external agencies

• Lime sludge recycled with Lime Kiln.

• Bellmer Press: It is screw press used for primary sludge dewatering. Inlet Cy

is 2% and outlet dryness is 55-60% which is used for board making by

external agencies

• 30455 Tons of waste paper/ board recycled as raw material through our De-

Inking Plant for the manufacturing of Writing Printing Paper & Board paper

Utilization of waste material as fuel:

2015-16 2016-17 2017-18Dry pith (Tons) 55508 47025 33952Wet pith (Tons) 53429 50405.2 50735W. Dust (Tons) 8916 10867 13686

Environmental Projects:Project List

3813

1400

118 280

2015 2016 2017 2018

Enviornment Project

Investment (Rs in Lacs)

Carbon Captured/ Sequestration/

GHG Inventorisation

• Eucalyptus clones are being developed in Mist Chambers and distributed to

farmers in nearby areas for sustainability of raw material.

• Discussions with State Govt. for plantation and assuring them two cycle in 10

years as against one cycle in 9.5-10 years.

3.81

3.65

3.45

3.20

3.30

3.40

3.50

3.60

3.70

3.80

3.90

2015-16 2016-17 2017-18

Ton Co2e

Green Supply chainBattery operated fork lift:Under Green supply chain we identified the 3

vendors & replace the 33 no diesel operated

forklifts/clamps by battery operated fork lifts.

Resulted saving of 290KL of diesel pa

S.No. PlantNo. of Fork lifts/Clamps

Contractor

1 WPP Plant 1 R.R.Associates

2 Bagasse Plant 1 R.R.Associates

3 Bagasse Plant 3 ECO INDUSTRIAL SERVICE

4 DIP 2 R.R.Associates

5 Recycle Plant 2 ECO INDUSTRIAL SERVICE

6 Recycle Plant 2 R.R.Associates

7 Tissue 4 R.R.Associates

8 Board Plant 1 R.R.Associates

9 Board Plant 8 ECO INDUSTRIAL SERVICE

10 Board Plant 9 Rahul Contractor

Total 33

Usage to LED Lights:

In Place of Conventional sodium vapour &

Metal halide lights, resulting in 247 KWH

saving in last 3 Years.

• Street Lights of colony & Plant Premises

•Inside Plant Lightning

IE3 Motors:

Usage of IE3 motors in place of old motors

(Rewinded more than 04 Times). This has

resulted in saving of 130KWH of electrical

energy.

System has been implemented that any

new procurement of motors will be

minimum IE3 Grade.

Replication arising out of best practices in Green supply chain :

Decrease in Coal Consumption:

Coal Consumption per ton of finished

product has been decreased from 1.28 to

1.17 Ton per ton of finish product

Increase in Recovery Steam Economy:

Recovery Steam Ratio has been increased

from 2.97 to 3.39 Ton per ton of Solid

1.28

1.26

1.18 1.17

2014-15 2015-16 2016-17 2017-18

Coal Consumption ( T/T of FNP)

2.973.02

3.24

3.39

2014-15 2015-16 2016-17 2017-18

Recovery Steam generation per ton of Solid

Replication arising out of best practices in Green supply chain :

Decrease in LPG Consumption:

LPG Consumption per ton of Tissue paper

production has been decreased from 90.63

to 57.78 Kg per ton of Tissue Paper

Production

Increase in CMG Consumption:

CMG Consumption per ton of Tissue paper

production has been increased from 0 to 29.07

Kg per ton of Tissue Paper Production

0.00

6.09

26.8729.07

2014-15 2015-16 2016-17 2017-18

CNG Consumption in Tissue Plant(Kg/Ton of Tissue Paper Production)

90.63 86.23

62.11 57.78

2014-15 2015-16 2016-17 2017-18

LPG Consumption in Tissue Plant(Kg/Ton of Tissue Paper Production)

CEO

EC Cell

Head Engineering

Organizational Set up for Energy Conservation:

Head Process

Production

Env & water

Power House Recovery

PARTA

Elect & inst

Store & purchase

Review Mechanism:

CEO (with all DRs)• Daily Review Meeting

• Monthly Plant Improvement Meeting

• Weekly Saving initiative Progress

• Monthly Profit & Loss review

Head Process & Head Engg•Fortnight Saving CAPEX review

•Weekly Shift in-charge meeting

•Weekly EC meeting

SBU HeadDaily Shop Floor Meeting

External Auditors

GPTWIMEA Audit

Energy Monitoring Format:

Visioning Exercise done through

LSIP (Large Scale Interactive

Participation) to capture

Developmental Initiatives

Involvement of Employees, Team Work in ENCON/Trainings

Kaizens/Visioning Exercise (2017-18)

S .No. Plant

From Associates From Staff Total

Generated Implemented Generated Implemented Generated Implemented

1 WPP 630 580 112 105 742 685

2 RGP Plant 853 742 271 255 1124 997

3 Bagasse Street 3906 3164 927 871 4833 4035

4 Recycle Street 1408 1324 289 272 1697 1595

5 Tissue Plant 277 263 72 68 349 331

6 Fiber Line 2678 2357 556 523 3234 2879

7 Board Planr 1852 1704 605 569 2457 2273

8 Recovery 3321 2889 717 674 4038 3563

9 Power House 3735 3100 467 439 4202 3539

10 ETP 903 885 113 106 1016 991

Total 19563 17007 4129 3881 23692 20888

Involvement of Employees, Team Work in ENCON

88% Suggestion Implemented

ISO 50001 is under implementation…

Corporate Social Responsibility:

Century cares for community at

large and strives to be a good

corporate and social citizen

through conducting medical

camps, Welfare, undertake

construction work of schools,

Roads near by area, drinking

water facilities, skill development ,

Education etc.

38

21

59

3

Total Projects Implemented UnderImplementation

To BeImplemented

Dropped

Project Status - Committed Last Year

Status of Energy Conservation Projects Committed last year

Project List

In 2017-18 % of investment for energy conservation projects on turnover is 0.61%

with a total investment of Rs 13.2 Cr

For 2018-19 % Separate budget of Rs 17 Cr has been allotted by the Management

Best Practices:

Condition Monitoring

• Roller Maintenance

• Steam Leakages

• Water leakages

• Air Leakages

Reliability Improvement through Route charts

• Bearing monitoring

• Web Inspection

• Thermography

• Relay testing

• Belt & oil checking

• Lifting, tool & tackle checking

• Pressure Vessel checking

• Meter calibration

• UPS redundancy checking

• Earth pit checking

• DCS redundancy Checking

Best Practices:

Regular emphasis on training & development

Consistence problem solving through system & processes

Every year on 14th Dec Energy conservation day celebrated in CPP.

Electrical safety Campaign for associates & staff members

Standardization of Vendors for procurement of Energy Efficient products like AC, Lightning, IE3 Motor, pumps, fans etc.

Electrical safety Campaign for associates & staff members

Lower Grid consumption during peak period

Daily Monitoring of all energy consumptions sources & corrections in defined time pattern

Awards & Recognitions:

Best performer Award in term of Energy

saving under PAT scheme cycle-I in the Pulp &

Paper Sector on Energy Conservation Day

(14th Dec 2017)

Energy efficient unit of India by CII for the

year 2003-04, 2006-07 , 2007-08 , 2014-15,

2015-16 & 2016-17.

1st Runner-up award for Best Paper in IPPTA

54th AGM & seminar 2018 at Delhi

Best Paper Award in IPPTA Zonal Seminar

2016

Received 1st prize in farmer fair

2013,2014,2015, 2016 & 2017

Best importer award in 2014 & 2015

Awards & Recognitions:

Received energy conservation award 2012

from UREDA with a cheque of Rs. 50000/-





Received national energy conservation

award for 2003-04 & 2005-06 from Govt. Of

India.

Received Indian paper manufacturers

association’s award for energy conservation

for the year 2002-03, 2003-04.

THANKS

Energy Conservation (Electrical) 17-18

S. No. Area of SavingInvestment

in lacs

Annual

Electrical

Saving (kWh)

Annual Electrical

Cost Saving (Rs

1PM3- By Voltage optimization of HT Transformer 308- (tap change from 5 to

3) - 5MVA transformer (270KW saving)0 2352000 108.19

2Power House- Optimize the 21MW TG Turbine voltage from 11.1kv to

10.95KV and save the energy in power house and PM3 plant (280KW

saving)0 2217600 102.01

3Power House- Joining the delivery headers of Boiler Feed Water pumps to optimizethe BFP running (250KW Saving)

35 2100000 96.60

4Compressor House- Replacemnt of 3stage CF compressor with 2 stage CFcompressor for Process air(Avg power cons for process air reduced from 18000units to 13000 units)

48 1825000 83.95

5Power House- Installation the VFD in Circulation Pumps of 16 MW TG Cooling Tower(112KW Saving)

5 887040 40.80

6Recovery- Two pumps were running at Evaps -II at each 2nd , 3rd , 4th & 5th effect,they were replaced with single energy saving pump at each effect, there by saving110 kWH

10 871200 40.08

7 Recovery- Enmas condensate pump stopped. 0 831600 38.25

8Recovery- One energy saving pump is running at Causticising Sump box as againstTwo

0 831600 38.25

9 Power House- Replacement of PA Fan of Boiler # 8 & 9 (75KW Saving) 40 609840 28.05

10RGP- One no. 160 kw vacc pp installed in place of 7 no's 37 kw vacc pp in sh. m/c(60KW Saving)

40 604800 27.82


S. No. Area of Saving

Investme

nt in

lacs

Annual

Electrical

Saving

(kWh)

Annual Electrical

Cost Saving (Rs

11ETP- Air line has been layed for air aeration from T.B.main header to equalition &off two root blowers (each22 kw) 0.05 345600 15.90

12Fiber Line: PRIMARY SCREEN ACCEPT PUMP & TERTIARY SCREEN FEED PUMPBYPASSED 0 336000 15.46

13PM4- UTM Pulper Agitators (42UD01 & 42UD02) were running idle. Conceptualchanges have been made in the DCS logic program. Now both agitators running for2 minute in every 40 minute interval.Motor running KW 68.2*2=136.4KW

0 334180 15.37

14Tissue- Installation of VFD over CCW water pump (534P03M2) Load recuced from49.4kw to 12 KW- saving of 37.4KW 1.2 327624 15.07

15Tissue- Refining load optimization and maintain Required 0SR-approx-40 KW powersaving and Tackle life also increased.(Approx 12 lacs saving due to Tackle life) 0 316800 14.57

16 Fiber Line: 110KW VFD Reshuffling HOT Water pump (Saving of 38.41KW) 0 308432.3 14.19

17 Fiber Line: 90KW VFD Reshuffling fresh water pump (Saving of 37.38KW) 0 300161.4 13.81

18 Fiber Line: 75KW VFD installation on Back water pump (Saving of 37.10 KW) 1.5 297913 13.70

19 Board Plant- Bye pass of one pump (37KW) in cooling water circuit (29 KW Saving) 0 250560 11.53

20Bag Pulp Mill- FILTERATE CHEST P/P-2 MOTOR REPLACED (132KW) WITH FILETERATECHEST P/P-3 MOTOR (90KW)- Saving of 25.9KW 0 205128 9.44



Investme

nt in

lacs

Annual

Electrical

Saving

(kWh)

Annual Electrical

Cost Saving (Rs

21PM3- BCTMP new pump installed with low capacity as Bagasse p/p 9MT wasrunning for 1MT (25 KW saving) 1.25 198000 9.11

22 Fiber Line: 45KW VFD Reshuffling Wash & Diln liq Pump (Saving of 24.28KW) 0 194968.4 8.97

23 Fiber Line: VINEER CHIPS RECHIPPER 3 NOS MOTOR SHUT 0 182000 8.37

24WTP:Pressure transmitter provided at soft water pump for Bagasse & Recycleplant.(20 KWH Saving) 0.1 172800 7.95

25Power House- To stop the Thermax Transformer 2MVA and shift the load on BHELTransformer for energy saving (17 kw saving) 0 148920 6.85

26 ETP- 2MVA One transformer has been stopped at old ETP (17 kw saving). 0 148920 6.85

27Compressor House- Bypassing of Compressor Pit Pump, by using line head todeliver water to Pump House ( A seal pit pump was used, now line is directlyconnected and pump is stopped.) (Saving of 15KW)

0 131400 6.04

28RGP- recirculation Pump 22kw motor stopped in sheeting machine (Saving of16.5KW) 0 118800 5.46

29 PM3- Tabulator bars installed in 12 nos. dryers. (15 KW saving) 14 118800 5.46

30 Bag Pulp Mill- VFD Provided in BLACK LIQUOR COOLER P/P (Saving of 16.1KW) 0.5 115920 5.33



Investme

nt in

lacs

Annual

Electrical

Saving

(kWh)

Annual Electrical

Cost Saving (Rs

31PM3- New Pump for screw press feeding provided (New P/P - 45Kw Old Pump -132Kw) - saving of 20KW 2 108000 4.97

32 Bag Pulp Mill- VFD Provided in BLOW TANK-1,P/P-1 (Saving of 14.95KW) 0.7 107640 4.95

33 Recovery- Taken out the Lump breaker at Enmas boiler 0 102960 4.74

34 RGP- Drum chipper stop in night shift and gantry crane stop (Ideal running stopped) 0 102600 4.72

35Fiber Line: 30KW VFD installation onTower scraper EOP tower (TSB-T 4004 B)-(Saving of 12.14 KW) 1.5 97484.2 4.48

36Fiber Line: 30KW VFD installation onTower scraper D1 tower (TSB-T 4004T) (Saving of 12 KW) 0.9 96360 4.43

37 Fiber Line: 75KW VFD Reshufflingliquor to recovery plant (Saving of 11.59 KW) 0 93067.7 4.28

38Power House- one tranformer of 12.5MVA stopped if grid load is less than 6MW(Saving of 21KW) 0 90720 4.17

39 Bag Pulp Mill- VFD Provided in WASH TOWER P/P-2 (Saving of 12.1KW) 0.5 87120 4.01

40 Bag Pulp Mill- VFD Provided in SCREEN TOWER P/P-2 (Saving of 12.1KW) 0.8 87120 4.01

41Bag Pulp Mill- By providing Star delta starter in SCREEN SURGE CHEST AGIT. (Savingof 8.34KW) 0.2 60048 2.76



Investme

nt in

lacs

Annual

Electrical

Saving

(kWh)

Annual Electrical

Cost Saving (Rs

42 Fiber Line: MV LAMP AND CFL REPLACEMENT BY LED LIGHTS (160 NO) 5.22 58976.7 2.71

43Fiber Line: 75KW VFD Reshuffling Wash liquor pump filtrate tank no.1 (Saving of6.75KW) 0 54202.5 2.49

44Fiber Line: 30KW VFD Reshuffling Discharge tank pump (standbye)- (Saving of6.7KW) 0 53801 2.47

45Tissue- Installation of VFD over LC cleaner dilution pump & CCW water pump(530P06) Load recuced from 11kw to 4.9KW- saving of 6.1KW 0.4 53436 2.46

46 Recovery- Stopped unnecessary circulation of RFO of BHEL/ABL when boiler is shut. 0 53064 2.44

47Recovery- installed vfd in place of control valve for sweerining pp-30kw inevaporator no-3 (5.9 KW saving) 1.5 46728 2.15

48Bag Pulp Mill- By providing Star delta starter in SCREEN TOWER AGIT. (Saving of6.16KW) 0.2 44352 2.04

49

WPP Pulp Mill- VAT Dilution Pump-4(changed with energy efficient pump, earlier HP75, new pump Hp-60) (Previous running load 51.7kw& new pump running load45.4kw) 5 44100 2.03

50ETP- Positive suction has been provided at 34 dia over flow pp -1 inplace ofnegative suction.App.5 kw 0.2 43200 1.99

51ETP- Positive section has been provided at 34 dia over flow pp -2 inplace ofnegative suction.App.5 kw 0.2 43200 1.99

52 PM3- 15 kw VFD provided in Warm Water pump (5 KW saving) 0.5 39600 1.82


S.

No.Area of Saving

Invest

ment

in lacs

Annual

Electrica

l Saving

(kWh)

Annual

Electrical

Cost

Saving (Rs

53RGP- Replacement of 67 no's 125/150 watt hpmv & 40 watt tube light fitting by 40watt LED fitting & 20 watt tube light fitting

4 37668 1.73

54WPP Pulp Mill- Twin Turbo Washer No-2, Motor speed reduced to 1000rpm insteadof earlier 1500rpm, this has led to drastic reduction in loading time from 2:15minto 1:30min. (Previous running load 19Kw & new pump running load 14)

0 35000 1.61

55WPP Pulp Mill- Clo2 stock Pump-1 VFD installed in existing motor (Previous runningload 14.0kw & new pump running load 5.0Kw) 0.8 35000 1.61

56WPP Pulp Mill- VAT Dilution Pump-3 (changed with energy efficient pump, earlierHP 75, new pump Hp-60) (Previous running load 29.8kw & new pump running load24.9kw)

5 34300 1.58

57WPP Pulp Mill- VAT Dilution Pump-1 (changed with energy efficient pump, earlierHP 60, new pump Hp-60) (Previous running load 23.8Kw & new pump running load19.2Kw)

5 32200 1.48

58 Board Plant-VFD insttaled in Speed sizer cooling water pump (11KW)- saving of 3KW 0.5 25920 1.19


S.

No.Area of Saving

Invest

ment

in lacs

Annual

Electrica

l Saving

(kWh)

Annual

Electrical

Cost

Saving (Rs

59WPP Pulp Mill- Fresh water Booster Pump-1 (Earlier Rating 75 HP new pump motorrating 20HP) (Previous running load 13.38kw & new pump running load 9.28kw) 2 25060 1.15

60Bag Pulp Mill- 45 KW MOTOR TAKEN IN LINE INSTEAD OF 132 KW MOTOR FOR BHDDRY PULP P/P (Saving of 23KW) 0 17273 0.79

61 WPP- Replacement of 26Nos HPMV with LED 40Watt 0.7 16133 0.74

62RGP- 5 nos 400watt HPMV light of Pulp Godown controled with timer & stoppedruning in day time 0 8760 0.40

63PM4 & tissue-Installation of LED lights(50 watt) in place of conventional light (125watt )-25 no 0.75 8212.5 0.38

64 WPP- Replacement of 40w tube light with 18w LED Tube light- 30Nos 0.05 4818 0.22

65RGP- Clo2 chemical pump interlocked with vacuum filter no 4 repulper to stop idleruning of Clo2 pump 0 985.5 0.05

Energy Conservation (Thermal) 17-18

S. No. Area of SavingInvestment in

lacs

Annual Electrical

Cost Saving (Rs

1Recovery- At Evaporator III, in daily sequence changing approximately 250 M3

of Condensate was being used and taken into WBL system for reprocessing0 170.75

2

Recovery- Steam temp was less than 435 degree centigrate & power house

facing problem with steam temp, Now Steam Temp is maintaining above 445

degree centigrate. This Achieved by proper maintainence of soot blowers

pressure & doing repetition in prone areas (Saving of 37KJ/T of steam

generated)

0 147.24

3Fiber Line: STEAM INTERLOCKINGS IN DIGESTER AREA (Total steam

Reduction - 0.05 Ton / Ton of Pulp)0 79.03

4

Fiber Line: Effluent heat recovery heat exchanger pipeline modified, initially it

was parallel system, we modified the pipeline to cascade system (the output

effluent of first HE used as input of second HE). It gave us 2.1° C temperature

gain.

0 29.05

5Board Plant-Setting of blow Valve in LP line, increase set point by 0.1 kg/m2 (

5T/day saving per day)0 20.82

6PM4- Auto temprature control to be incorporated in speed flow false ceiling to

avoid rejection of paper during winter season due to dripping of water. (saving pf

3.84T/day)0.1 17.69

Energy Conservation (Thermal) 17-18

7Recovery- Enmas Boiler Indirect heater condensate connected to flash vapour

heat recovery system (0.12T/hr)1 11.99

8

Fiber Line: INSULATION OF TANKS & PIPE LINES (Some Pipelines in Cooking

Area (HBL, DPL, MP Steam & HWL) Insulated, Also Condensate tank in ClO2

Plant, WL, DPL & Discharge tank top insulation Underprogress).- Total Heat loss

reduction, kCal/hr - 88396.57

1.09 11.04

9Board Plant-Inslullation done on steam and condensate system, two trap

provided in false celling system (saving of 116293Kcal/Hr) equivalent to

1151Tons of steam4.65 14.53

10 Fiber Line: CHILLER MACHINE NO 2 HTHE REPLACED (Saving of 0.19T/hr) 7.6 20.14

11Board Plant-Auto tube cealning system installed in VAM system, nrew coling

tower installed( Steam saving of 0.15T/Hr)12 15.90

12Recovery- Enmas Boiler condensate evacuation system of Primary &

Secondary Air Heater & utilizing flash steam in air heaters. Savings MP steam 8

TPD and 9 TPD thus estimated Saving 60 70.80

13Fiber Line: Opti-batch Adoption (saving 2KW/ton, Gain of Steam due to low

cooking temp – 0.05 Tons /Ton of Pulp, MP steam replaced by LP steam

resulted gain of 14 Ton steam/ day)200 175.04

14Power House- Increase in TG Power generation by 1.6 MW in comparision to

2016-17 at same condensing,by running 16 MW TG during running of ABL

Boiler. (coal aving 1.5T/hr)815 629.69

Environmental Project 15-18

S. No Name of the Environment ProjectInvestment (Rs

in Lacs)Year

1 Bagasse Pith Separation System & Anaerobic Treatment Plant 1000 2015

2 Up gradation of 25MLD effluent treatment plant 1100 2015

3Fugitive Emissions control system for Coal Crushers, Depithers

and Talcum Unloading station100 2015

4Upgradation of biological reactor by installation of difusses

areation system1136 2015

5 Purification of CMG to replace LPG at Tissue Plant 476 2015

6 Installation of diffused areation system in equilization tank 750 2016

7 Installation of Tertiary treatment at unit no 1 (ETP) 650 2016

8 Filter Press at ETP 38 2017

9 ESP for Limekline-1 80 2017

10 Knotter for pith dewatering at BVF 80 2018

11 Installation of spiral ladder for stack monitoring at PH & recovery 150 2018

12 BHEL ESP retroffit 25 2018

13 Dust Sepration system at power House 25 2018

5610.57

Future Plan for next Year: 18-19 (Elect.)

SR NO. PLANT SCHEME SAVING (KW )

1 PM4SKY PIPE TO BE INSTALLED IN PLACE OF PLANT LIGHTING (CUUTER AREA ,M/C FLOOR ,GODOWN PM4 ,DIP MAIN FLOOR ,DIP GODOWN) 70.5

2 PM4 AGITATORS OPTIMISATION TO BE DONE 15

3 PM4 SIZE PRESS TOP ROLL TO BE MADE SHUT WHEN SIZE PRESS NOT IN LINE 30

4 PM4 SWITCHING OF Acs AS PER TEMPERATURE 2

5 PM4 VFDs TO BE RUN IN ENERGY SAVING MODE 20

6 PM4 SINGLE M/C CHEST PUMP TO RUN 35

7 PM4 HP SHOWER P/P TO BE CHECKED

8 PM4 COOLING TOWER UPGRADATION TO BE CHECKED

9 PM5 SKYPIPE TO BE INSTALLED AT M/C FLOOR AND HOOD AREA 30

10 PM5REWINDER TRIM BLOWER TO BE MADE RUN ONLY WHEN REWINDER IS RUNNING ( 2 NOS. OF REWINDER) 15

11 PM5 BALE PULPER TO BE RUN IN STAR DELTA STARTER TO BE CHECKED

12 PM5 VAC. PUMP VFD CONTRLLING TO BE CHECKED

13 POWER HOUSE BOILER FANS FROM 8 TO BE INSTALLED IN BOILER 5 20

14 POWER HOUSE COOLING SYSTEM ON COMMERCIAL OFFICE WATER LEAKEGE TO BE ARRESTED TO BE CHECKED

15 POWER HOUSE POWER FACTOR IMPROVEMENT BY COMMISSIONING OF APFC TO BE CHECKED

16 POWER HOUSE SCREENING AREA TO BE ENLAREGED .PLANT RUNNABLITY WILL DECREASE TO BE CHECKED

17 POWER HOUSE WORM WHEEL GEAR BOX TO BE REPLACED TO BE CHECKED

18 POWER HOUSE VOLTAGE OPTIMISATION OF TRANSFORMER.BOILER NO. 8 25

19 POWER HOUSE MILL COMPRESSOR TO BE OPTIMISED TO BE CHECKED

20 POWER HOUSE 63 MVA T/F COOLING FANS CAN BE STOPPED ACCORDINGLLY 3

21 RECOVERYIDLE EQUIPMENT TO BE STOPPED AND PUMPS WHICH ARE RUNNING ON THROTTELING TO BE ANALYSED TO BE CHECKED

22 RECOVERYENMASS BOILER ID FAN SECONDARY 280 KW FLUID COUPLING ,VFD TO BE INSTALLED TO BE CHECKED

23 RECOVERY 5 METER CUBE CONDENSATE RECOVERY TO BE CHECKED

24 RECOVERY VACUUM PUMPS COMMON HEADER AND OPTIMISATION TO BE DONE TO BE CHECKED

25 RECOVERY ENERGY EFFICIENT MOTORS TO BE REPLACED 220 KW 20

26 RECOVERY EVAPORATOR COOLLING TOWER TO BE RETROFITTED TO BE CHECKED

27 RECOVERY WPP STREET TO BE MADE SHUT 11

28 WPP AGITATORS TO BE MADE ON STAR DELTA STARTER ACCORDING TO NEED 10

29 WPP AGITATORS IMPELLORS TO BE CHANGED FOR ENERGY SAVING 10

30 WPP MECHANO PUMPS TO BE CHANGED TO BE CHECKED


31 WPP APFC TO BE INSTALLED FOR POWER FACTOR IMPROVEMENT TO BE CHECKED

32 WPP VAC PUMP EFFICIENCY TO BE INCREASED TO BE CHECKED

33 WPP ONLINE DSR INSTRUMENT TO BE INSTALLED FOR REFINERS TO BE CHECKED

34 PM3 DC MOTOR TO BE REPLACED WITH AC MOTOR ON CUTTER NO. 2 3

35 PM3 6.6 KV MOTOR TAP OPTIMISATION 250

36 PM3TWO NOS DC MOTORS COOLING FAN ARE RUNNING CONTINUOUSLY .TO BE CONTROLLED BY LOGIC 1.5

37 PM3 3RD PRESS MOTOR BLOWER TO BE REMOVED 7.5

38 ETP IN COAGGULATION AREA 2 NOS 22 KW MOTOR MADE SHUT 44

39 ETP 2 PUMPS TO BE REPLACED WITH ENERGY EFFICIENT PUMPS TO BE CHECKED

40 WORKSHOP COLONY QUARTERS LIGHTING TO CHANGED WITH LED LIGHTS

20041 WORKSHOP TIME SWITCH TO BE INSTALLED IN COLONY

42 RGPNEW VACUUM PUMP TO BE INSTALLED IN TRESH AREA ,37 KW MOTOR TO BE SHUT( 7 NOS) 33

43 RGP CHIPPER LIGHTING TO BE MADE SHUT IN NIGHT 2

44 FIBER FIBER CHIPPER TO BE MADE SHUT IN TEA TIME 20


45 FIBER RECHIPPING SYSTEM TO BE MADE SHUT 20

46 FIBER APFC TO BE INSTALLED TO BE CHECKED

47 FIBER COOLING WATER SUMP LEVEL CONTROLER TO BE INSTALLED 4.5

48 BOARD ROOF LIGHTING TO BE REPLACED WITH LED LIGHTS 73.7

49 BOARD HPMV LAMP TO BE REPLACED IN STAIR CASE WITH TUBE LIGHT 1

50 BOARD LT CAPACITOR BANK TO BE INSTALLED FOR NON VFD LOAD TO BE CHECKED

51 Mill Wide Installation of VFDs 310

52 Mill wide Replacement of energy efficient Motors with IE3 grade(Line Loss Reduction) 170

53 Mill wide Roof top Solar 68

54 Mill Wide LED Lights 130

55 Mill Wide Heat Pump for ACs 40

56 Mill WideMill Wide 08 transformers to be stopped( Having Loading <30%)-Reduction in Line Losses 136


Future Plan for next Year: 18-19 (Thermal)

S.No Opportunity.

Saving Potential (in

Lacs)

1 Mill Wide Insulation 57.56

2 WPP

Black liquor dilution Control: There is 3% Heigher Moisture identified in WPP pulp mill vinear Chipps after

dyenss screw in comparasion with Fibre Line.20M3/Day water addition can be reduced. 16

3 Bagasse Pulp

Black liquor dilution Control:

13 Nos Pumps identified where sealing water getting mix up with Black Liquor. Saving Opportunity: 184

lac/Annum.(94M3/Day excess water mixing in to WBL).184

4 WPP

Uncontrolled Heating: 1)Gum cooker direct heating through 1"Line .No control on temperature.

2)Starch Cooker no temeprature control. To Check

5 PM#3

Uncontrolled Heating:Uncontrolled steam Heating in BCTMP chest.

Bentonite preperation Tank Uncontrolled Heating.Batch Processs.18hrs./24Hrs.

False sealing temperature no control.To Check

6 PM#4

Uncontrolled Heating: LBKP and NBKP pulper No control on temperature.

Bentonite preparation Tank Uncontrolled Heating. Batch Processs.18hrs./24Hrs. To Check

7 PM#5 Uncontrolled Heating:Yankee coating Release chemical preparation Tank. No control over temperature To Check

8 PM#6 Uncontrolled Heating:Uncontrolled steam Heating in wire part false sealing. To Check

9 Fibre Line Dead Load Control: 6mt 6"line at Clo2 Plant. To Check

10Bagasse Pulp

Dead Load Control:6"LP steam Line going to Bottom screw Nozzles are not in use.Can be

removed.Length around:10 mtTo Check

11PM#3Dead Load Control:M ain steam Line to Film press walk way heating line is found not

required. To Check

12WPP

Steam Trap Optimization: PV Blower 4 Nos trap to be provided .present there are no traps.

10 Nos steam traps required.To Check

13PM#3

Steam Trap Optimization: New trap Provided in film press heating system.

3 traps require on False sealing. To Check

14Mill Wide 6% Condensate recovery 212

13RGPMoisture Control on final Product: Moisture variations reduced to 4to 8 from earlier 4 to

15% To Check

14WPP Heat Exchangers and Filters: Correction of Pre Heaters -2 Nos. 60

13Fibre Line Heat Exchangers and Filters: Installation of WL heat Exchanger 462

14Fibre LineOther saving oppurtunities:LP Steam reduction by using flash team of HBL H/E

Condensate 100

Savings expected as on Date(In lacs) 1091.56

Future Plan for next Year: 18-19 (Thermal)

Water Conservation Schemes Implemented

S.No Description Area YearWater Saving

(M3/Hr )

1 Use of Chlorine back water in Static Mixer and Unbleached 4% Tower. RGP 15-16 20

2Re-use of pumps gland cooling and sealing Water in washing section at RGP Pulp

mill. RGP 15-16 20

3 Closed loop pulp washing WPP 15-16 75

4 Reuse of soft water from coating plant of Board M/C to Fiber line Clo2 Plant Fiber line 16-17 20

5 Reuse of clearifired back water from board stock to fiber line PM-6 Tower. Fiber line 16-17 60

6 Reuse of Final Effluent for irrigation in Plantation and green belt. Entire Plant 16-17 25

7 Use of tertiary treated Effluent in ETP in place of Fresh Water. ETP 16-17 50

8 Use of tertiary treated Effluent for Log Washing & Chips Washing in Fiber Line. Fiber line 16-17 20

9 Use of Tertiary treated Effluent for Fire Hydrant & General cleaning purpose. Entire Plant 16-17 50

10 Re use of unbleached thicker backwater at washer no 4 (RGP) RGP 17-18 60

11Use of tertiary treated water for dust control at power house by installation of 160

no water sprinklersPower House 17-18 50

12 Machine back water used in D washer mat spray & repulper. Bagasse plant 17-18 25

13Installed auto controller in VAM system soft water make up tank, saving in soft

waterBoard Plant 17-18 2.5

14Relocation of cooling tower in cooling system, impact get better delt temprature so

less makeup water required, saving in soft waterBoard Plant 17-18 7

484.5


S.No. Title of ProjectSavings Achieved

p.a. (Rs .in lacs)Status

1 Bagasse-Turbulator bar(10KW Saving) 3.34 Implemented

2 Tissue-Waste heat recovery (.490 ton/Hr steam saving) 38.63 To Be Implemented

3 Recovery-Producer gas optimization (1300 lts per day furnace oil saving) 120.68Under Implementation

4 RGP-Vacuum pump optimization (90KW saving) 30.06 Implemented

5

Power House-Synchronisation of TGs with Grid Power to save opportunity based Power Saving & Production loss during paper machines change over (250KW Saving)

136.62Under Implementation

6 RGP- Energy efficient motors (72KW Saving) 26.60 Implemented

7 RGP-Motors Replacement ( Second phase)-41KW Saving 15.14 To Be Implemented

8 All Plant- Mill wide solar system of 1.5MW- first phase 273.24 To Be Implemented

9 All Plant- Mill wide VFD 78.69 To Be Implemented

10 All Plant- Energy efficient motors 44.45 To Be Implemented

11 All Plant- Optimization of vacuum pump 72.86 To Be Implemented

12 All Plant- Millwide LED lighting 25.12Under Implementation

Status of Energy Conservation Projects Committed last year13 RGP-Centricleaners bypass during PGP run, Power saving 125KWH 22.77 Dropped

14 RGP-Chemical mixer no.1 bypass. 14KWH 3.28 Dropped

15 RGP-PGP in slurry 172.36 Implemented

16 WPP-Energy efficient pumps changing WPP 7.29 Implemented

17 WPP-Mixing chest pump to be changed 3.64 Implemented

18WPP-Twin turbo washer motor to be replaced by low RPM motor ( 22 KW 1500 RPM to 22 KW 1000 RPM )

1.67 Implemented

19 WPP-upgradtion of high pressure compresser to low pressure 36.43 Implemented

20 Bagasse-VFD in Warm water Pump 1.82 Implemented

21 Bagasse-3 bar fresh water pump replecement 3.64To Be Implemented

22 Bagasse Pulp Mill Pumps changing 2nd Phase 24.29 Implemented

23Bagasse-Instrument air consumption reduction by 5% by monitoring and attending leakages (present cons. 325m3)

2.19 Implemented

24 Bagasse-Press pit agitator and pump stoppage 32.94 Dropped


25 Bagasse-PV blower system upgradation 0.43 To Be Implemented

26 PM4-Agitators RPM reduction 13.36 Implemented

27 PM4-Intermittent stoppage of intermediate chest agitator 1.58 Implemented

28 PM4-Stoppage of skimmer zone blower 1.46 To Be Implemented

29 PM5-Reduction of working compressed air pressure from 7.5 to 6.6 bar 0.61 Implemented

30 Recovery-To replace Enmas boiler start-up vent valve as is passing 43.01Under Implementation

31 Recovery-To provide de-superheating station for Evap I. 43.01Under Implementation

32Recovery-To stop unnecessary circulation of RFO of BHEL/ABL when boiler is shut. There by saving steam & Power

45.22 Implemented

33Recovery-To provide 12 valves at 4th & 5th effect of size 28” (2 no.), 6" (6 No.s) & 32” (4 no's) manual valves for bypassing the bodies at Evap-II.

15.64 Implemented

34 Power House-Replacement of PA Fan of Boiler # 8 & 9 27.32 Implemented

35Power House-Joining the delivery headers of Boiler Feed Water pumps to optimize the BFP running

91.08 Implemented

36 To install the VFD in Circulation Pumps of 16 MW TG Cooling Tower 36.43 Implemented

37Fiber Line-Line modification of Effluent heat exchanger to get more heat recovery.

46.88 Implemented

38 Clo2 Plant-Replacement of HTHE of chiller B 17.20 Implemented

19th CII NATIONAL AWARD FOR “ EXCELLENCE IN ENERGY ...

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Transcript of 19th CII NATIONAL AWARD FOR “ EXCELLENCE IN ENERGY ...