INDIAN PULP & PAPER TECHNICAL ASSOCIATION

30.08.2018

0

40000

80000

120000

160000

200000

1960 2018

20000

165000

Cap

acit

y, t

/ an

nu

m

ISO-9001 / ISO-14001 / OHSAS 18001 / FSC certified company

Practising TPM & achieved GreenCo Gold Rating

50% energy generation from renewable sources

6,000 Ha

of pulp

wood

plantation

Product Portfolio – Writing, Printing, Posters & Speciality Boards

COMPANY PROFILE

• Erode

• Tirunelveli

• Kolkata

• Hyderabad

• Mumbai

• Ernakulam

• Delhi

• Bangalore

2

Green

Liquor

Black

Liquor

PROCESS AT UNIT

PULPING PROCESS WASHING / BLEACHINGRAW MATERIALS

PAPER MACHINEEVAPORATORRECAUSTICIZER

ROTARYLIME KILN RECOVERY BOILER FINISHING / DISPATCH

BurntLime

LimeMud

CHEMICAL RECOVERY Black liquor

Green liquor

White liquor

3

We, at SPB are committed to continually improve our Energy Efficiency by:

analysing the present status of energy generation and consumption in our

mill

fixing energy consumption targets for each department

monitoring energy consumption on a daily basis

conducting periodic Energy Audits

fixing the yearly target for Energy reduction and implementing the Energy

Conservation Schemes to achieve target.

involving and motivating all employees to reduce energy consumption

08.02.2016 K S Kasi Viswanathan

Managing Director

ENERGY POLICY

4

SEC TREND – LAST 3 YEARS5

0.585

0.531

0.514

0.440

0.480

0.520

0.560

0.600

2015-16 2016-17 2017-18

MT

OE

/ T

ON

OF

FIN

ISH

ED

PR

OD

UC

T

Key Points

8% reduction in Specific steam consumption

5% reduction in coal consumption

SEC REDUCTION OVER LAST 3 YEARS

6

9.34

8.668.57

8.00

8.40

8.80

9.20

9.60

2015-16 2016-17 2017-18

SS

C (

t/t)

1656

1603

1658

1560

1600

1640

1680

2015-16 2016-17 2017-18

Impact of production loss

due to water crisis

SP

C (

kW

h/t

)

SPC REDUCTION OVER LAST 3 YEARS

SSC REDUCTION OVER LAST 3 YEARS

7

Bench

mark

Gap

Analysis

Action

Plan

National

Best

ROAD MAP TO ACHIEVE NATIONAL BEST

8

MT

OE

/ t

1500

1658

1350

1425

1500

1575

1650

1725

National 2017-18

9.00

8.57

8.20

8.40

8.60

8.80

9.00

9.20

National 2017-18

0.607

0.514

0.440

0.480

0.520

0.560

0.600

0.640

National Avg(2014-15)

2017-18

Source: Gazette notification dt. 31.03.2016

Source: CPPRI

Specific Energy Consumption

Specific Steam Consumption Specific Power Consumption

SS

C, (t

/t)

SP

C, (k

Wh

/ t

)

BENCHMARKING - NATIONAL VS SPB

9

2015-16

0.585 MTOE / T

2016-17

0.531 MTOE / T

2017-18

0.514 MTOE / T

ENCON ROAD MAP

CPP retrofit from BFB to

Sprouted fluidized bed

Power saving: 350 Lakh kWh

Spiral heat exchanger BL/WL

Steam saving – 2100 t

Replacement of old reciprocating

compressor with new screw compressors

with HRU

Power saving – 3.65 Lakh kWh


TARGET2018-19

0.498 MTOE / t

RDH return condensate to CPP


1921

25

0

5

10

15

20

25

30

2015-16 2016-17 2017-18

No

. o

f s

ch

em

es

1116

110196

0

200

400

600

800

1000

1200

2015-16 2016-17 2017-18

Rs

. L

ac

s

Investment

Energy Conservation Schemes

Good

ECS with investment 39

ECS with minimum investment 26

ENERGY CONSERVATION PROJECTS

IMPLEMENTED IN LAST 3 YEARS

11

32%

177

1430

0

300

600

900

1200

1500

1800

Savings with “Minimum Investment”

Savings with Investment

Last 3 years Energy Saving Projects

26720 tons

400 Lakh kWh

PROJECT SUMMARY (2015-16 TO 2017-18)R

s i

n L

acs

Steam Saving

Power Saving

12

Last 3 years Energy Saving Projects.pptx

Description Cost savings

(Rs. Lakhs)

Annual

Energy Savings

(Electrical)

‘000 KWh

Annual

Energy Savings

(Thermal)

t of steam

Installation of LED fittings – mill wide 1.61 35.818 -

Chipper – 3 – Main motor capacity

reduction from 500 HP to 375 HP 5.76 128.0 -

Yankee Machine – Upgradation of DC

drives with AC drives and AC motors 3.78 84.0 -

Boiler – 11 De-aerator feed pump –

Replacement of DOL starter with VFD 2.16 48.0 -

CPP ELGI Air compressor – B –

Replacement of Star Delta Starter with

VFD

1.089 24.192 -

ENERGY CONSERVATION PROJECTS (2017-18)

Note: Cost savings were calculated from the date of installation to 31.03.18

13


(Rs. Lakhs)

Annual

Energy Savings

(Electrical)

‘000 KWh

Annual

Energy Savings

(Thermal)

t of steam

Boiler House – New screw Air

compressors in place of reciprocating

Air compressors

1.17 26.0 -

Primary ETP Washer drives 1 & 2 –

Replacement of Dyno drives with VFD 0.163 3.629 -

Boiler – 11 TA Fan – Replacement of DOL

starter with VFD 0.432 9.6 -

PRDS – 1 leak off steam diverted for RO

water heating 3.256 - 486

Project with minimum investment


14Note: Cost savings were calculated from the date of installation to 31.03.18


(Rs. Lakhs)

Annual

Energy Savings

(Electrical)

‘000 KWh

Annual

Energy Savings

(Thermal)

t of steam

CPU pump speed control logic for uniform

flow distribution in PHE 1 & 2 7.316 - 1092

PRDS – 1 [105/30 KSC] 2500 # isolation

valves introduced at BFP & PRDS station 2.457 54.6 -

Boiler – 10 FD Fan – C - New LT motor with

VFD

5.67 126.0 -

PM 1-4 – 3” line with air receivers with ring

line minimizing pressure drop 2.32 51.552 -





(Rs. Lakhs)

Annual

Energy Savings

(Electrical)

‘000 KWh

Annual

Energy Savings

(Thermal)

t of steam

Boiler – 10 PA pressure reduced from

820mm WC to 780mm WC 0.105 2.325 -

Boiler – 10 Burner Air fan stoppage [start

up] with air admittance through SA 0.023 0.504 -

CPP DSH pump with VFD set to auto mode

through Pressure transmitter 0.405 9.0 -

B 7 Coal feeders – Isolator provided for

taking care of individual feeder output 0.168 - 25





(Rs. Lakhs)

Annual

Energy Savings

(Electrical)

‘000 KWh

Annual

Energy Savings

(Thermal)

t of steam

Clarified Green Liquor tank insulation 15.54 - 2320

Hot water from Hot water tank to LMCD 7.71 - 1150

Switch from MP to LP steam in Starch

cooking 9.855 219.0 -

Boiler – 11 compressor pressure

reduction from 6.0 to 5.8 bar 1.026 22.8 -

RDH – Bellow type mechanical seal

changed to plain 54 O-ring in 1 of 2

Pressure screens. 70 KW stopped

10.78 239.5 -





(Rs. Lakhs)

Annual

Energy Savings

(Electrical)

‘000 KWh

Annual

Energy Savings

(Thermal)

t of steam

MG 1st press vacuum pump 75HP

stopped higher capacity 2nd press

bottom felt utilized for both application

6.166 137.025 -

Specific Steam consumption reduction

in PM 1-4 consolidated 11.189

-

1670

Boiler 10 - Sonic soot blower for

marginal performance improvement

through reduced dust deposition on SH

coil

2.0

- Coal – 30 Ton

Total 102.15 1221.545 Steam – 6743

Coal – 30




INNOVATIVE PROJECTS19

Limited Resources…

Unlimited Ideas…

INNOVATIVE PROJECT – 1

Trigger for the project

While going in for replacement with Energy Efficient Screw Air compressors, it was

found that the air used for oil cooling was being discharged to the ambient as hot air.

Hence, it was decided to recover the heat from oil cooling for gainful purpose viz., for

Boiler feed water heating, resulting in lowered steam consumption in CPP - Deaerator.

Heat Recovery Scheme along with Energy Efficient Screw Air compressor

for Co-generation Power

INNOVATIVE PROJECT – 1 (Contd..)

21

Available Heat

94%

9% heat

From drive motor

13% heat

From After cooler

72% heat

From Oil cooler4% heat

Inside the canopy

2% heat

Through canopy

Total Power

100%

ELGI Unit – Heat available for recovery


22

Waste Heat Recovery – Technical data

Model HR -110

Type Brazed

No. of plates 100

Oil Synthetic

Hot side Oil / 76 – 81 ºC

Cold side Boiler feed water / 36 ºC

Recoverable heat 89.14 kWt / 0.077 MKcal (76%)

Feed water flow 2 TPH

Feed water heated 30 ºC to 70 ºC

Deaerator steam reduction 2.5 tpd


23

Air filter

Intake valve

Air end

Air oil separator tank

Minimum pressure valve

Thermal valve 1

Thermal valve 2

Plate type Heat Exchanger

Oil cooler

1

2

3

4

5

6

7

8

9

1

2

3

4

5

6

7

8

9

Air Oil Mixture

Air

Oil

Water

Waste Heat Recovery – Flow sheet


24

Elgi Energy Efficient Screw Air Compressor (761 CFM) – PG test results

Air compressor FAD 746 – 765 CFM at 45 ºC

Air compressor discharge pressure 5.45 KSC

Power consumption 110 KW

SPC reduction 7%

Oil temperature 76 – 81 ºC


25

How & Why it is Innovative

Integrating the HRU – Air compressor unit with HP Captive Cogeneration plant for

WHR – Power generation would be “First of its kind” for Cogeneration CPP

Gains

Power consumption reduction through replacement with EE screw AC 1000 kWh / day

LP steam reduction through WHRU 2.5 tons / day

Replication Potential in Indian MarketThe above Energy Conservation Scheme can be replicated

by all the industries for their new air compressors.

Annual GHGE reduction ~500 tCO2e


26

INNOVATIVE PROJECT – 2

Trigger for the Project

With increased deposit on pressure parts in general and Super-heater coils in

particular, the super heater exit flue gas temperature started shooting up. This in turn

reflected in marginal increase in flue gas back-end temperature. As steam soot

blowers could not be located in Super-heater zone due to horizontal super heater coil

design, alternative concept was gone in for in the style of Sonic soot blowing

Energy Conservation through Sonic soot blower in CPP – HP AFBC Boiler


28

Sonic soot blower – Working Principle

Sonic soot remover is based on the

principle of “Kinetic Activation” of the dust

particles, using sound waves generated by

a “Sound generator, operated by

compressed air”.

A microprocessor based programmer

controls the complete operation of the

system

The sound generator sent out powerful

sound signals, of low frequency and high

intensity, at suitable intervals, inside the

Boiler which cause the soot deposits to

loosen and break away the bonds from the

heated surfaces.

These loosen deposits may then drop down

in to the collection hoppers or be carries

away with the flue gas

Sonic soot blower Tube bundle

Flue gas stream


29

Sonic soot blowing operates continuously on line in successive short cycles

Cleaning in Successive short cycles

Initially, ash particulates

land on tube surfaces

and stay there

Since, “Off” time in

the cleaning cycle is

short, only a small

quantity of ash

particulates can land

and will remain quite

loose as there is not

enough time for it to

compact

When cleaning cycle starts, sound waves come

in and clean up easily. The cycle repeats every

few minutes successively to keep the tube

surfaces clean


30

How & Why it is Innovative

Sonic soot blowing for horizontal SH coil section of HP AFBC Boiler is probably “First

of its kind” for Cogeneration CPP

Gains

HP steam generation enhancement in Boiler 10 2.5 TPD

Imported coal consumption reduction 0.4 – 0.5 TPD

Annual GHGE reduction ~70 tCO2e

Replication Potential in Indian MarketThe above Energy Conservation Scheme can be replicated by all

the industries.

Based on the success achieved, replication was done through

installation of two more sonic soot blower units in Economizerbank


31

0

20

40

60

80

100

2015-16 2016-17 2017-18

51.65 53.53 49.08

48.35 46.47 50.92Non Renewable Energy %

Renewable Energy %

%2017-18

Renewable Energy % reduced due to

Low pulp production due to water crisis

Recovery Boiler stopped for spout seal box

leakage (4 days)

16 MW TG overhauling shut (16 days)

Low firing in Recovery Boiler for attending to

ESP no. 1 air infiltration (20 days)

UTILIZATION OF RENEWABLE ENERGY

Black Liquor generation, t

240000

250000

260000

270000

280000

2015-16 2016-17 2017-18

251769

271018

251238

32

Solar Energy utilization at various areas of the Mill

CANTEEN

GUEST HOUSE

PROJECT OFFICE

UTILIZATION OF RENEWABLE ENERGY

PETROL BUNK

33

8100

90309190

7200

7600

8000

8400

8800

9200

9600

2015-16 2016-17 2017-18

Qu

anti

ty, T

on

sQ

uan

tity

, To

ns

Bagasse pith waste – Fuel for Boiler (Beyond gate)

Effluent waste discharge for sugar cane cultivation – Aided by solar energy

11300

8600 9000

0

2000

4000

6000

8000

10000

12000

2015-16 2016-17 2017-18

Waste component End use

Bagasse Washing – Bio

methanation

Guest House

Bio methanation of food

wastes

Cooking –

Chummery Hostel

Miscellaneous waste as fuel for others

2% increased from last

year

5% increased from last

yearQ

uan

tity

, To

ns 6960

9872

4677

0

2000

4000

6000

8000

10000

12000

2015-16 2016-17 2017-18

Chipper dust waste – Fuel for Boiler (Beyond gate)

UTILIZATION OF WASTE AS FUEL

34

2.461

2.08 2.02

0.00

0.50

1.00

1.50

2.00

2.50

3.00

2015-16 2016-17 2017-18

tCO

2 / t

of

pro

du

cti

on

18% reduction from last 2

years

GHG INVENTORIZATION

35

UNIDO had selected SPB-Erode for first Pilot plant study related to GHG

Inventory

Total Emissions inside the mill 330 “000 tCO2e

Biogenic Emission 320 “000 tCO2e

Scope – 3 Emission 26 “000 tCO2e

Carbon sequestration 780 “000 tCO2e

Climate positive +130 “000 tCO2e

CRADLE

TO GATE

COMMUTING & BUSINESS TRAVEL

GHG Emissions &

Carbon SequestrationGrid – 128.5

MU / Annum

10534 tCO2e

Export Power

23612 tCO2e

Chemicals

Imported pulp

1676 TPA

3385 tCO2eFinished Paper

121594 TPA

Pulp to T ‘Veli

23087 TPA

500 tCO2e

Calcination

195964 TPA

14155 tCO2e

Furnace Oil

8239 TPA

25678 tCO2e

Coal

128659 TPA

252857 tCO2e

Forest Wood

Tree Farming

8 Lakh TPA

7.8 “000 tCo2e

Bagasse

8000 TPA

GHGE INVENTORY (EMISSION INTENSITY)

Science Exhibition conducted by the Students of SPB Primary school on

4th Dec ‘17 with Central themes as Global Warming, GHG Emission

reduction measures with special emphasis on Tree Farming with factual

demonstration.

GHGE AWARENESS FOR YOUNG GENERATION

37

SPB is committed to improve environmental efficiency in the supply chain by reducing

the resources such as Energy, Water, Material and GHG emission across major

suppliers and in Supply Chain by:

Sourcing of Raw material from environmentally and socially responsible sources

Maximizing the usage of Eco friendly chemicals and energy efficient equipments

Maximizing the use of Recovered paper in the paper furnish

Following the 3R principle of Reduce, Reuse and Recyclable

Conducting awareness programs on Environmental impacts for vendors and

suppliers and other stake holders

Creating awareness about GSC to critical vendors and to help them go for ISO 14000

certification and to prioritize buying from ISO vendors

Improving the efficiency of the suppliers by audit, training and improvement

suggestions

08.02.2016 K S Kasi Viswanathan

Managing Director

GREEN PURCHASE POLICY

38

INFORMATION ON PROJECTS IMPLEMENTED

Action Gains Status Impact

Introducing Bio-fertilizers

in SPB Nursery

Reduction of

Chemical fertilizer

consumption

Implemented

Eco-Friendly & Climate

Friendly (N2O-GHG

emission reduction)

OBA powder (Instead of

liquid) procurement

Easy handling &

transportation

reduction.

Avoiding usage of

plastic carboys

for OBA storage

Implemented

Diesel reduction

(Logistics). GHG

emission reduction

marginal

Imported FO with lowered

sulphur content

Reduction in

sulphur content

during this period

& beyond

Implemented SO2 emission in RLK

stack gas would be

lowered; besides the

lime product quality /

purity would be higher

39

INFORMATION ON EVALUATION DONE

Vendor Name 07-12-17

S. No Period

Water

Cons

m3 / MT

Power

Cons

KWH / MT

Steam

Cons

MT / MT

14001

Certificate

Waste Disposal Any other

Environ

monitoring

system

Logistic

Optimisa

tionGeneration

Kg/MT

Mechanism

followed

1 2013-2014 48888 2.0 MW -42885 KL/YR

Treatment

through

ETP and

disposal

through

CETP of

GREEN

society

NIL NIL

2 2014-2015 48600 1.92 -42632

3 2015-2016 48888 1.85 -42885

4 2016-2017 46900 1.7 -41141

Reduction (13 to 16) %

5 Baseline 47000 1.7 -

6 2017-18 46000 1.5 - 40351

Khyati Chemicals Pvt Ltd

40

AWARENESS ON FOREST FRONT

AWARENESS ON ENVIRONMENTAL IMPACT

MT

GCC – Fiber substitution (Quality improvement)

3616 3912

6162

0

1500

3000

4500

6000

7500

2015-16 2016-17 2017-18

33654099

4540

0

1000

2000

3000

4000

5000

2015-16 2016-17 2017-18

Native Starch - Fiber substitution

2.32

2.26

1.88

0.00

0.50

1.00

1.50

2.00

2.50

2016-17 2017-18 2018-19

MT

%

Sulphur content % in Imported Furnace oil over the years

INFORMATION ON BENEFITS ACHIEVED

42

Scheme generation

Initial Assessment

Feasibility Analysis

Implementation

SEC reduction

ENCON IMPLEMENTATION METHODOLOGY

Monitoring

system

Shift wise

monitoring

RCA &

corrective

action

Fortnightly

monitoring

Daily

monitoring

Energy

Management cell

& HODs

Chairman, MD,

P (T) & VP (T)

HOD

P (T) & VP (T)

SIC & HOD

ENERGY MONITORING

METHODOLOGY

Aim

43

Projected savings

At SPB, we steadfastly recognize the value of team work in all our Energy

conservation activities

PAT Team

Energy Team

TEAM WORK IN ENCON

44

Together Everyone Achieves More

Mill energy performance is being

reviewed by Chairman fortnightly

On the Job training Class room training For school children

Through News letters

AWARENESS & TRAINING PROGRAMME

Kaizen SheetActivity KK JH QM PM SHE OTPM DM ET SPB LTD, ERODE

Loss No./ Step

P

Result Area P Q C D S M

1. Dept. : Boiler 2. Machine/Area : PRDS 1 / CPP3. KAIZEN Theme : Energy conservation 7. Idea : Heat recovery from PRDS 1 leak off steam4. Problem /Present status : 8. Countermeasure : 10. Bench markPRDS 1 (105 / 30 KSC) steam valve passing 30 tpd

Leak off steam from PRDS 1 was diverted to condensate tank no. 3 & 4 to heat the RO water

Target

Before After Kaizen start 01.08.17

Deaerator feed temp 60 ºC Deaerator feed temp 62 ºC

Kaizen finish 30.11.1711. Team members : S Balaji, Supervisor K Gunasekaran, Operator

5. Analysis : 9. Results : Deaerator steam consumption reduced by 2 t / day

12. Expense: 13. Benefits : LP steam saving - 730 t / annum (Rs. 4.75 Lacs)14. Scope & plan for Horizontal Deployment

5. RCA : S.No M/c No Target Dt Responsibility Status

Kaizen SheetActivity KK JH QM PM SHE OTPM DM ET SPB LTD, ERODE

Loss No./ Step

P

Result Area P Q C D S M

1. Dept. : Boiler 2. Machine/Area : FD fan "C" / Boiler 103. KAIZEN Theme : Cost reduction 7. Idea : To install new LT motor FD fan (FD fan C) with VFD4. Problem /Present status : 8. Countermeasure : 10. Bench markFor Boiler 10 combustion, FD air is being supplied through FD fans A & B (HT motors), which consumes power more.

New FD fan with LT motor was procured, erected and commissioned

Target

Before After Kaizen start 25.07.17

With FD fan A & B, Power

consumption 585 kWh

With FD fan A & C,Power

consumption 564 kWh

Kaizen finish 20.09.1711. Team members : S Sathishkumar, Supervisor K Sowndararajan, JO

5. Analysis : 9. Results : Boiler "Off range" can be avoided due to installation of additional energy efficient fan in case the existing one of the two fans fails.

12. Expense: Rs. 50 lacs13. Benefits : Power saving - 504 kWh / day Cost saving - Rs. 8.28 lacs / annum14. Scope & plan for Horizontal Deployment

5. RCA : S.No M/c No Target Dt Responsibility Status

PROJECTS IMPLEMENTED THROUGH KAIZENS

Mill SSC – Mar ‘18

8.28

8.908.72

8.038.22

8.58

8.39

7.49

9.30

11.02

8.88

8.15

8.08

8.25

8.36

7.35

8.67

8.39

8.88

8.30

8.778.61

8.22

8.088.09

7.55

7.92

8.40 8.33

7.76

7.96

4.00

5.00

6.00

7.00

8.00

9.00

10.00

11.00

12.00

13.00

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Norm 8.44 t/t

DAILY MONITORING SYSTEM

Mill SSC, SPC & Dept wise SSC, SPC is being reviewed in

Production meeting daily by P (T) and VP (T)

Achieved 8.34 t/t1) RDH more steam consumption (60 t )

2) Low wet lap production (50 t)

3) Low Eq. Finished Production (310 t)

1) Good Eq. Finished production (390 t)

2) Good wet lap production (110 t)

3) All dept SSC are within the norm

47

Awards &

Recognition

Cash award by Chairman Mementos by Executives

48

Amount approved for Energy Efficiency improvement Projects by Management

FINANCE RESOURCE ALLOCATION

1105

11

1116

10100 110

59137

196

0

200

400

600

800

1000

1200

Thermal Electrical Total

2015-16

Rs

in

Lac

s

2016-17 2017-18

75672

1116

% INVESTMEMENT ON TURN OVER

79557

110

74525

196

2015-16 – 1.47% 2016-17 – 0.14%2017-18 – 0.27%

Turn over (Rs. In Lacs) Investment (Rs. In Lacs) 49

GREENCO CERTIFICATION - 2017

TNPCB ENVIRONMENT AWARD - 2017

50

HONOUR FOR SPB

IPMA – Energy Award 2015 CII – Excellence in Energy Efficiency Unit 2016

IPMA – Environment Award 2017 CII – Energy Efficiency Unit 2017

51

NATIONAL RECOGNITION

52

“The future depends on what we do in the present.”

- Mahatma Gandhi

INDIAN PULP & PAPER TECHNICAL ASSOCIATION

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