R.Muralidaran, Head - Energy Cell Iswara Prasad S, Energy Manager M Phaneendhra, Energy Cell Member

Transcription

1 R.Muralidaran, Head - Energy Cell Iswara Prasad S, Energy Manager M Phaneendhra, Energy Cell Member

2 Mill Introduction ITC Ltd., PSPD, Unit: Kovai is located 42 km North of Coimbatore, Tamil Nadu Acquired from BIPCO in March 2004 Manufacture Duplex Board from 100 % recycled fiber Production capacity of 1,20,000 Tons / year Employment to people Certifications: ISO 9001 : 2015; ISO : 2015; OSHAS : 2007 Certified for Forest Stewardship Council (FSC) First Indian Manufacturing unit to gain WWF s Global Forest Trade Network Membership ITC PSPD Unit Kovai First Company in the Pulp and Paper Sector to receive GreenCo Platinum rating CII Excellent Energy Efficient Unit 2010, 14, 15, 17

3 Sheeters Water from River Sp. Water: 8 m3/t Process Flow Water Treatment DM Plant Fuel Cogen 8MW Emission: SPM <30ppm Windmill 7.5MW Waste Paper Waste Paper Waste Paper Pulper Pulper Pulper Screen Centri cleaner Hot disperser Screen Centricleaner Hot disperser Screen Centricleaner Hot disperser Stock Preparation Petax Filter TL wire FL wire BL wire Condensate Treated Effluent Reuse Press & Temse c ETP Steam Dryers, MG, Calender Board machine Coater Treated Effluent for Irrigation Sp. Power: 543 Units/T Rewinder Reel & Rewinder TSS <30ppm Finishing House Sp. Discharge = 5.5 m3/ MT D e s p a t c h

4 Specific Power (kwh/mt of FNP)

5 Specific Steam (MT/MT of FNP)

6 Benchmarking with World Class Performance

7 Roadmap for Global Benchmark Sl.No Description Area Savings / Day Sp Power 1 Vacuum pumps replacement BM Starch Agitator 2 replacement BM Trim Pulper BM Separator pumps BM Total BM Mac Cell Feed aeration Pump -3 Stock Mac Cell Feed aeration Pump -4 Stock Mac Cell Feed aeration Pump -5 Stock Energy Efficient Agitators - 8 Nos Stock Total Stock Feed water makeup Pump Utility Open well submersible Pump (Intake) Utility Discfiltter Inlet Pump Utility Thickner sludge pump Utility Primary underflow pump_non clog Type impeller Utility Total Uty Reel lamination hydraulic pump FH Compactor Stoppage FH Total FH Total Potential

8 PAT Cycle 2 Performance PAT Cycle ecerts achieved

9 Year Summary of Energy Savings & Investment Sum of Annual Energy savings (Lakh Units) Sum of Total Annual Savings (Rs Lakhs) Sum of Invest. Made (Rs Lakhs) Payback (Months) Year Sum of Annual Steam savings (Tonnes) Power Steam Sum of Total Annual Savings (Rs Lakhs) Sum of Invest. Made (Rs Lakhs) Payback (Months)

10 VFD related schemes Sl: No: Title of Energy Saving project implemented Energy Saving Per day in kwh Annual Total savings (Kwh) Annual Electrical Savings achieved Units Million Rs Millio n Total Annual Savings Rs Million Invest. Made Rs Million 1 VFD for ETP 4 Aerators VFD for FL QCC VFD for F/L sec. coarse screen feed pump VFD fordm 2 agitator VFD fo chest no: 12, 13 & VFD for Top HD ring dilution pump VFD for HD tower pump top VFD for Filler blend chest pp Chest VFD for New TCC feed pump VFD for Secondary fine screen feed pump VFD for 1st stage coarse screen feed pump VFD for Top silo Consistency dilution pump VFD for Chest no5 pump Investment in last 3 years Rs 29 Lacs, Savings achieved Rs 48 lacs Payback months

11 Efficient pumps & agitators Schemes Sno Title of Energy Saving project implemented Energy Saving Per day in kwh Annual Total savings (Kwh) Saving s Year of Implemen tation Annual Electrical Savings achieved Units Million Rs Million Total Annual Savings Rs Million 1 Energy Saving Agitator for FL Blend Chest April' Energy Saving Agitator for FL HD TOWER April' Energy Efficient Makeup water pump Dec' Energy Efficient Recovery fibre chest pump Jan' Energy Efficient Vac Cooling Tower pump Jan' Energy Efficient Process Cooling water Pump Jan' Invest. Made Rs Millio n Payback months Energy Efficient Vacuum hot well pump Jan' Energy Efficient Krofta Feed Pump Jan' Energy Efficient New SS Tank Feed Pump Jan' Energy Efficient Recovered Fibre pump Jan'

12 Efficient pumps & agitators Schemes Sno Title of Energy Saving project implemented Energy Saving Per day in kwh Annual Total savings (Kwh) Savings Year of Impleme ntation Annual Electrical Savings achieved Units Million Rs Million Total Annual Savings Rs Million 12 Energy Efficient Krofta High Pr Pump Jan' Energy Efficient CPU Feed Pump_UTY Dec' Energy Efficient UF Feed Pump_Uty Dec' Energy Efficient RO transfer pump Dec' Energy Efficient Aerators for ETP May' Energy Efficient ETP Discharge Pump May' Energy Efficient ETP Discharge Pump Feb' Energy Efficient Main cooling Tower Pump CCk starch preparation agitator-1 replacement Feb' June Invest. Made Rs Millio n Payback months Investment in last 3 years Rs 75 Lacs, Savings achieved Rs 83 lacs

13 Lighting & AC related schemes Sl: No: Title of Energy Saving project implemented Energy Saving Per day in kwh Annual Total savings (Kwh) Annual Electrical Savings achieved Units Million Rs Million Total Annual Savings Rs Million Invest. Made Rs Million Payback months 1 Replacement of BM 30 MH Hibay with 14 Plasma Lamps Replacement of 400W Himast Metal Halide with Plasma lamps in 4 Himast (Lorry Yard, WTP, FHS & WS) Replacement of 43Nos BM, Stock 0m 125W MH Wellglass with 40W LED Lamps Replacement of 40Nos BM, Stock 0m 70W MH Wellglass with 40W LED Lamps Occupancy Sensor installation for Admin office Replacement of Office Lightings with 36W LED Replacement of Office Lightings with 36W LED Replacement of 150MH MH hibay with 80W LED Hibay in stores

14 Lighting & AC related schemes Sl: No: Title of Energy Saving project implemented Replacement of 250W MH hibay with 100W LED Hibay in inside WPY Replacement of 150W MH flood light with 50W LED Flood light across building periphery Replacement of 2X400W MH flood light with 2X200W LED Flood light in WPY feeding area Energy Saving Per day in kwh Replacement of 150W MH flood light with 70W LED Flood light in Outside WPY 58 Replacement of 150W MH lamp with 50 watts LED FLP fitting in FHS 96 Annual Total savings (Kwh) Annual Electrical Savings achieved Units Million Rs Million Total Annual Savings Rs Million Invest. Made Rs Million Payback months Energy efficient inverter air conditioners across mill Investment in last 3 years Rs 68 Lacs, Savings achieved Rs 22 lacs

15 Steam: Actions Taken : Sno Description Source Energy Savings (Tons/Day) 1 Using flash steam in CCK from air tunnel separator Internal 25 2 MP Desuper heating station Shifting to BM from Utility Internal 5 3 Fuel Shed Internal Replacement of 30 stationary siphon with rotary siphons External Mp Steam line pressure drop reduction Internal TG casing Modification Internal 15

16 Innovative Project 1 Edge drying IR lamp Automation wrt GSM IR dryer was installed to reduce edge moisture. Electrical IR dryer consists of four IR cassette One quartz plate to protect lamp from damage. Reflectors to extract 100 % heat from lamp. Blower to cool the gold plated reflector. Each IR cassette is 18.5 kw. Total 72kW. Image depicts top view of the system. IR dryer worked at a fixed set point. Machine Direction IR Edge Dryer system

17 Infra red dryer IR Dryer at MG cylinder

18 IR WORKING PRINCIPLE Reflective tile Cold air from blower Blower Lamp-1 Lamp-2 Lamp-3 Lamp-4 Quartz plate to protect lamp Heat from IR lamp absorbs moisture from paper board Paper direction

19 Modification done Current input to Power controller varied Heat output also varied proportionally GSM is linked with Heat Output of lamp Before After Savings in Equip KW KW Kwh IR dryer IR set point tab in DCS 6 Lacs / Annum benefit at NIL investment

20 Innovative Project 2 STARCH PREPARATION BATCH REDUCTION Starch is used for surface sizing on board at size press. Starch is prepared at coating kitchen in starch cooker. Normal starch preparation is 10 batches per day during lower GSM run and at maximum machine speed. Source of Idea: Operator Kaizen Weight per batch was increased No of batched reduced from 10 batches to 8 batches/day Starch cooker in CCK Web passing through size press Starch sizing pool

21 Operator Kaizen Batch wt Steam in T Before Power in kw Machine speed No: of batches 650 Kg mpm 10 Batch wt Steam in T Power in kw Machine speed No: of batches 750 Kg mpm 8 After Energy Before (Benefits/Annum) After (Benefits/Annum) Difference Power units units 2374 Units Steam 2142 T T 210 Tonnes

22 Innovative Project 3 AHU Outdoor Unit Optimisation Package AHU OD Units are operating continuously to meet the temperature Setpoint. Analysis found that hot air is getting short circuited due to wind direction. Idea came from AC technician to over the issue. Partition barricades were installed & operating hours reduced by 50% Outdoor Units are running intermittently, not continuous. (Each 5.5TR) WIND DIRECTION Building Indoor Hot air Circulating back to suction due to wind

23 Modification on ODU Before After ODU operating time reduced upto 50% Power Savings 130 KWh / day per AHU, Investment : NIL ITC PSPD, Unit: Kovai Rs 10 Lacs / Annum Benefit achieved

24 Renewable Sources Utilization of Agro Residue Biomass in Co-Generation System: Plant Details - 8MW Cogeneration with 60TPH steam generator. Fuel used: Predominately Biomass Co-fired with fossil fuel. Biomass : De-oiled Rice Bran, Saw Dust, Wood Chips, Charcoal dust Fossil Fuel: Coal, Lignite Biomass consumption: 69,392 MT ( ) Utilization of renewable Windmill Power for Production Plant Details 1.5MW X 5 Nos = 7.5MW Windmill 200 Lac Units Generation Potential / Annum

25 On-Site Renewable Energy Generation Renewable energy contribution to total energy generated Saw Dust 24.6% 58.1% DOB Charco al chips Saw Dust DOB Charco al Powder Bio-fuels in Comparison Bio-fuels in Non-availability of Saw Dust being compensated by Byproduct Fuels

26 Waste Material as Fuel Saw Dust DOB / Paddy Husk Wood chips Charcoal dust Charcoal Chips Cashew nut Shell Matchstick Key criteria for consideration are - Availability (as byproduct from other plants). - Road distance from plant (transportation cost). - Alkali content.

27 Unit Kovai Power Source (%) 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Cogen Biomass Windmill Cogen fossil State EB % Power Source was from Renewable in

28 Utilization of Waste Material ETP Sludge 100% sludge generated is reused in process 5 TPD on dry basis being recycled ETP water About 40% of water being recycled. 800 m3 per day recycled for process.

29 Tonnes of CO2 Tonnes of CO2 Tonnes of CO2 GHG Emission Inventorization For the year , yet to be ratified by third party % reduction Tonnes of CO Scope- 1 Scope- 2 Scope

30 GHG Management Systems Quality Management - GHG Emission Inventorisation Source ITC s Sustainability Report 2017 ITC s Sustainability Report 2017 ratified by KPMG.

31 GHG Management Systems Quality Management - GHG Emission Inventorisation

32 GHG Management Systems Quality Management - GHG Emission Inventorisation

33 GSC Key developments 1. Education/Awareness to 31 critical vendors on Energy, Waste reduction, water reduction etc., till date Vendors were audited on key environmental performance and target were set for coming years to improve 3. Good work at vendor place is being recognized and Innovative projects on environment is recognized in big forum 4. Hand holding for Going green helped one of our vendor to get certified GreenCo- Gold under SME category 5. Unit has short time and log time actions for Proximity sourcing and vendors development

34 Green Supply Chain - Outcome Included as a part of Vendor Evaluation Criteria Internal Procurement of energy efficient equipment Reduction in RM Imports by 38 % in last three years Awareness Training given to 91% of the Critical Vendors Target set after Audit for 30% of the Critical Vendors Vendor Achievements through Improvement Projects M/S Fimakem 11% in Power & 8% in Water M/S Surya 7.4% in Waste M/S Beekay 33% in Waste

35 GSC Internal Energy Efficiency as part of All Procurements Energy Efficient Equipment for all new procurement All the new procurement are evaluated based upon the energy efficiency as one of the main parameter

36 Education and Awareness Creation on GSC Critical Vendors list S No Vendor Category Training Program 1 Karur KCP Packkagings Ltd Manufacturing Completed 2 Sree Sakthi Paper Mills Ltd Manufacturing Yet to complete 3 Sapthagiri Packagings Manufacturing Completed 4 Tamilnadu Synthetic Packagings Ltd Manufacturing Completed 5 Klene Paks Ltd Manufacturing Completed 6 Techno Boards Pvt Ltd Manufacturing Yet to complete 7 Beekay Industries Manufacturing Completed 8 Wow Initiative Collection & Segregation Completed 9 Varalakshmi Starch Industries Pvt Ltd Manufacturing Completed 10 Fimakem India Limited Manufacturing Completed 11 EICL Limited Manufacturing Completed 12 Ivax Paper Chemicals Limited Manufacturing Completed 13 Triveni In-organics Pvt Ltd Manufacturing Completed 14 Suriya Cutting Works Manufacturing Completed 15 Shree Aranganaathar Paper Converters Converter Completed 16 Sai Ram Paper Convertors Converter Completed 17 Sri Venkateswara Transport Transport Completed 18 Excel Woven Sacks Private Limited Manufacturing Completed

37 Education and Awareness Creation Vendors & Delegates Attendance Sheet Training & Awareness Program on GreenCo

38 Old Monitoring system Vendor Evaluation Curren t Environmental performance is included in Vendor Evaluation System procedure 38

39 Vendors Meet and GSC Awareness Training by CII TOPICS COVERED Global Warming Carbon footprint Energy Conservation Water Conservation GHG Emission Material Conservation Waste Reduction Logistic Optimization

40 Vendor Location initiatives on GSC Individual lighting switches Rain water Harvesting Pallets out of waste wood Flooring for raw materials

41 Employee involvement Kaizen Index UOM : No.of Kaizens / Per Employee per Month

42 EnCon Kaizen Employees Contribution 42

43 Sample Kaizen From shopfloor Back 43

44 Best practices on Energy conservation Forum for sharing ideas across divisions Intranet for sharing Employee ideas across Departments PSPD Energy meet & Training All Unit Energy Cell Members meet for 3 days Cross Unit Learning Expertise session for technology advancement CII Also shared several case studies

45 Best practices on Energy conservation As a part of Energy Cell, evaluation of the equipment were done and Continuous Action were taken to replace the less efficient equipment. EnCon investment was 0.3% of Turnover in Open Capex scheme to implement ideas without any delay.

46 Best Practices - Capex Structure 1 Specified > 300 Lacs 2 3 Clubbed > Upto 300 Lacs (Planned) Flexible - Upto 50 Lacs (Unplanned) Value increased from 15 Lacs to 50 Lacs Ideas generated with potential savings can be proceeded anytime thru Flexible.

47 Energy Management Cell & Energy Manager Energy Management Cell Members S NO Name Role Responsibilities of Energy Manager 1 R.Muralidaran Energy Cell Leader 2 Iswara Prasad Energy Manager & BM representative 3 S.Rajaram Energy Manager & Uty Representative 4 N.Vijaykumar Compressed Air Manager & FH AET Energy Cell Member 5 Phaneendhra Utility AET Energy Cell member 6 V.Abinesh Stock AET Energy Cell member 7 S.Rajendran Stock AET Energy Cell member 9 Jasper Devapaul Board M/C AET Energy Cell member 10 JegadheeshKumar Board M/C AET Energy Cell member 47

48 Monthly reviews pertaining to Energy Efficiency Structure of Reviews including Energy Management Cell Monthly review at OGM meetings by the USB Cross functional Energy Management Cell holds weekly meetings to review the energy consumption and initiates Energy Conservation Projects Daily area wise Energy consumptions monitored, reviewed in AET meetings and updated in AET Boards

49 Daily Area Wise Tracking Daily area wise Energy consumptions monitored, reviewed in AET meetings and updated in AET Boards

50 Weekly EnCon Cell Review Cross functional Energy Conservation Team holds weekly meetings to review the energy consumption and initiates Energy Conservation Projects

51 Monthly review at OGM meetings by Unit Head

52 Energy Cell Celebrations Energy Conservation Day World Water Day World Environmental Day Ozone Day

53 CII Paper tech take aways-2017 Anaerobic for etp and generating methane gas. Shoes press viability & Twin roll press CFD analysis Automatic paper testing system for Labs. Soot blowing using thermocompressor Swedish Neutral - To locate earth fault Danfoss - ESS Power storage and demand management Forbes marshall - steam optimisation High eff boiler feed pump and low dp valve. UASB Upflow blanket for secondary sludge IMBR technology Bio cleaner technology for secondary sludge liquidation.

54 Awards & Achievements First Greenco Platinum rated Paper Mill in India, 2015 CII National Award Safety award & 2015 National Safety Council of India Productivity Award 2013, 14 Coimbatore Productivity Council Excellent in Energy Management 2014, 15, 16 CII National Award Best Environmental performance-innovative Project, 2013 CII National Award 1 st Position at Green Award 2013 TNPCB, Government of Tamil Nadu 2 nd Position at Green Award 2014 TNPCB, Government of Tamil Nadu EHS Excellence Award, 2013 CII National Award 5 Star Safety Rating, 2007, 08, 10, 11 British Safety Council 5 Star Environment Rating, 2011 British Safety Council International Safety Award, 2010 British Safety Council Globe of Honor for Environment,2011 British Safety Council Excellent Water Efficient Unit, 2007, 08, 09, 11 CII National Award Excellent Energy Management, 2010, 14, 15, 17 CII National Award National Energy Conservation Award, 2010 Bureau of Energy Efficiency

55 Water positive for 16 years, Carbon positive for 13 years, Solid waste recycling positive for 11 years THANK YOU