Presented by TNPL Energy Team Members

Transcription

1 Presented by TNPL Energy Team Members

2 COMPANY PROFILE 1985 Commissioning of PM # 1 (Beloit Walmsley, UK) 1995 Commissioning of PM # 2 (Voith Paper, Germany) 2002 Rebuild of PM#1 and speed up of PM# Life Cycle Extension of PM#1 and Commissioning of new HW Street and ECF bleaching 2011 Commissioning of PM #3 (Voith Paper, Germany) 2015 Commissioning of Multilayer Double Coated Board Plant (Voith Paper, Germany) 2015-BOARD MACHINE # PAPER MACHINE # PAPER MACHINE # PAPER MACHINE #1

3 CAPACITY GROWTH

4 POWER SCENARIO TNPL is 100% self sufficient in power About 2.0MW of surplus power generated from TGs is exported to TANGEDCO Power from Wind Farm is exported to the grid

5 COMPANY PROCESS Baggase HardWood - Tafcon - Captive Plantation - Farm Forestry Waste Paper - Global procurement - Procurement from local universities and govt. offices Sugarcane field Sugarcane Sugar Factory Sugar Paper Bagasse Pulp Bagasse

6 REDUCTION IN SEC IN LAST 3 YEARS SPECIFIC CONSUMPTION OF POWER Consumption kwh/t Year Consumption kwh/t

7 REDUCTION IN SEC IN LAST 3 YEARS SPECIFIC CONSUMPTION OF STEAM Consumption T/T Year Consumption T/T

8 REDUCTION IN SEC IN LAST 3 YEARS SPECIFIC CONSUMPTION OF WATER Year Consumption Cu.M/T

9 HOW CLOSE TO GLOBAL BEST IN SEC TNPL Plant is Unique in its operation with largest Bagasse based Paper Manufacturing unit and there is no identical Mill for comparison. Hence the performance of TNPL could not be directly compared with other Mills. However our comparison with average national and international data shows that TNPL is amongst the best energy efficient units globally

10 HOW CLOSE TO GLOBAL BEST IN SEC TERI Energy and Environment Data Diary and Yearbook (TEDDY) 2014/15: Energy Consumption The pulp and paper industry is also highly energy intensive, where energy cost accounts for about 16% 25% of the cost of production of paper. The consumption of steam and electricity per tonne of paper production in India are about tonnes and kwh respectively. Total Energy Cost as % of Manufacturing Cost Global Average SEC Steam Electricity India Average TNPL TNPL

11 HOW CLOSE TO GLOBAL BEST IN SEC S.No. Particulars Power Steam water Source 1 Global Industrial Efficiency Technology Data Base 2 National CPPRI 3 TNPL * Perform Achieve Trade (PAT-I) Unit Baseline Avg. Notified SEC toe/tonne Targetted SEC toe/tonne Achieved SEC toe/tonne * No. of ECERTS achieved Perform Achieve Trade (PAT-II) Unit Baseline Avg. Notified SEC toe/tonne Targetted SEC toe/tonne

12 ENERGY SAVING PROJECTS IN LAST THREE YEARS Total Encon Projects Annual Electrical savings Achieved Annual Thermal Savings Total Annual savings Investm ent made Year Nos. Units Lakhs Rs. Lakhs Tons of Fuel - Imp.Coal Furnace Oil in KL Rs. Lakhs Rs. Lakhs Rs. Lakhs

13 ENERGY SAVING PROJECTS WITH ZERO COST INVESTMENT Year Total Encon Projects Total No. of Zero Investment projects Total savings from zero investment projects in Rs. Lakhs

14 ENCON PROJECTS IN (ELECTRICAL ENERGY SAVINGS) S.No 1 2 Description Stopping of Power Boiler 5 fly ash compressors and making use of available compressed air from Boiler-6 &7 fly ash system Electrical savings Lakh kwh Rs. Lakhs Total Saving s Rs. Lakhs Invest ment Rs. Lakhs By shifting the filtrate receiving tank from ground floor to first floor, LMCD Filtrate Pump was stopped Reduction of Vacuum Pump pulley size and there by speed of the vacuum pump is reduced in Lime Mud dewatering area Replacing 400 nos. of 36W tube lights by 400 nos. of 18W LED Lights in Admin block

15 ENCON PROJECTS IN (ELECTRICAL ENERGY SAVINGS) S.No 5 Description Installing 14Nos of Tubular Day Light device in place of 400W metal hallide lamp in paper godown Electrical savings Lakh kwh Rs. Lakhs Total Saving s Rs. Lakhs Invest ment Rs. Lakhs Down sizing of 22KW water pump for cement plant from BR#3 by 15KW pump Installation of VFD for Caustisizing plant (25 KW) first stage slackers sump box pumps Stopping of dregs filter in Caustisizer plant (74 KW)

16 ENCON PROJECTS IN (ELECTRICAL ENERGY SAVINGS) S.No 9 Description Reduction of POW#1 Hydraulic oil motor rating from 160KW to 132 KW Electrical savings Lakh kwh Rs. Lakhs Total Savings Invest ment Rs. Rs. Lakhs Lakhs Removal of one aqua collection conveyor of 5.5kw capacity in CBP#3 Replacement of 110 KW Depither motor by 55 KW motor Modification of Pith Distribution system and removal of a conveyor at Pith yard Stopping of Pith Horizontal conveyor and Pith Elevating conveyor of Boiler

17 ENCON PROJECTS IN (ELECTRICAL ENERGY SAVINGS) S.No Description Installation of VFD for Cloudy water pump (power reduction from 120 KW to 108 KW) in Paper Machine # 1 Installation of VFD for Cross travel (power reduction from 20 KW to12 KW) in Maintenance crane Electrical savings Lakh kwh Rs. Lakhs Total Invest Savings ment Rs. Lakhs Rs. Lakhs Replacing the End section rope carrier DC motor with AC motor (elimination of 11.4 KW) Stopping of Lip opening Shower Pump (elimination of 15 KW) equipment Upgrading of Warm water Pump in Paper Machine #1 by replacing 2 Nos. of 110 kw pump with 1 No. 160kw pump

18 ENCON PROJECTS IN (THERMAL ENERGY SAVINGS) S.No 1 2 Description Thermal Energy Savings by taking Recovery Boiler-3 wash water in WWL tank instead of WBL tank Usage of 6891 MT of Wood Dust/ Bark in Power Boilers Thermal savings Imp. Coal (MT) F.Oil (KL) Rs. Lakhs Total Savings Rs. Lakhs Invest ment Rs. Lakhs ,53,225 M 3 of Bio gas consumption in Power Boilers 59,53,510 M 3 of Bio gas consumption in Lime Kiln

19 UTILISATION OF RENEWABLE ENERGY SOURCES Types of RES Energy Generated (Lakh kwh) Annual savings Rs. Million Energy Generated (Lakh kwh) Annual savings Rs. Million Energy Generated (Lakh kwh) Annual savings Rs. Million Wind Solar Solar Energy 2 Nos of 3 Kw Solar Panel installed in TNPL Wind Farm 37 Nos of solar water heater installed in TNPL housing colony 5 Nos of 42 W Solar Street lights installed in TNPL Housing Colony 11 Nos of 42 W Solar Street lights installed in TNPL Wind Farm

20 UTILISATION OF WASTE MATERIAL AS FUEL Type of waste material used Quantity of waste material used ( MT) Equivalent qty. of conventional energy of fuel used (tons or kl of fuel) Bio mass Bio gas-'000m Black liquor solids Type of waste material used Annual savings Rs.Million Waste fuel as a percentage of total energy Bio mass Bio gas-'000m Black liquor solids TOTAL

21 GHG INVENTORISATION S.No. Year Total Emission CO 2 e MT

22 ENCON TEAM CGM (Commercial and E&I) Team Head AGM(R&D) Convener AGM(Energy)/Energy Manager Co-ordinator Pulpmill Paper Machine SRP Energy Members AGM(Inst.) SM(Elec.) SM (Pulp) SM(Pulp-Mech) Members AGM(Paper) SM(Mech) SM(Elec.) SM(Inst.) Members SM(SR) PE(Elec.) PE (Inst.) Members SM(Elec.) SM(Energy.Maint.) SM(Energy-Process) SM(Energy-Process) M(Inst.)

23 ENERGY MANAGEMENT SYSTEM

24 ENERGY MONITORING SYSTEM

25 EMPLOYEE INVOLVEMENT AND TEAM WORK Efficient Management of Electrical Power Systems and Energy Conservation for Executives held on 12 th & 13 th April, 2018 conducted by M/s. Ensave Consultancy and Training Pvt. Ltd, Chennai. Awareness training on ISO 9001:2015 & QMS 14001:2015 for workmen held on 14 th & 15 th May, 2018 conducted by M/s.Bhargav Management Consulants,Thiruvananthapuram

26 Innovative project #1 INSTALATION OF PLOUGH ARRANGEMENT IN COAL CONVEYOR BACKGROUND OF THE PROJECT: Two coal crushing system are available for preparation of coal. Two system were operated independently for feeding coal to different boilers. Two conveyors were interconnected by erecting a plough arrangement. One system was stopped permanently due to this modification. Power saving was achieved due to this modification.

27 INSTALLATION OF PLOUGH ARRANGEMENT IN COAL CONVEYOR Boiler 4 BC 10 BC 9 New Ploughing Conveyor

28 PLOUGHING ARRANGEMENT Total Power saving units /annum and Cost saving Rs Lakhs. Replication potential : It has a very high replication potential as this concept can be used in material handling belt conveyors system in power plants with zero investment.

29 Innovative Project #2 STOPPING OF BOILER # 5 FLY ASH COMPRESSOR PROJECT DESCRIPTION : Boiler # 5 (AFBC) was commissioned in the year 2000 and Boiler # 6 (AFBC), Boiler # 7 (CFBC) were installed & commissioned in the year 2010 and 2013 respectively. Each boiler was installed with separate air compressors for ash handling (2 compressors for each boiler, out of which, one will be in service and other will be in standby)system. Interconnection of boiler#5 fly ash handling air line with Boiler#6 & 7 fly ash handling air Loading of boiler#6 & 7 fly ash compressors to maximum capacity to cater the boiler#5 requirement Eliminating the operation of boiler#5 fly ash compressor

30 STOPPING OF BOILER # 5 FLY ASH COMPRESSOR

31 STOPPING OF BOILER # 5 FLY ASH COMPRESSOR Investment : Investment for the erection of 150 NB new pipe lines for interconnecting the Fly ash systems is Rs. 5 Lakhs Saving details : Power savings per day, after stopping the Boiler # 5 Fly ash compressor = kwh Cost Savings (Power Rs.3.89/kwh *2220.3kwh) = Rs /day Cost Savings per annum (350 days * ) = Rs lakhs Water is a resource which needs to be used meticulously and saved if possible. By stopping the reciprocating compressors cooling water consumption is totally eliminated which is a great saving on the resource to the tune of 2,52,000 m3/annum Replication Potential: The same can be replicated where a battery of compressors is running and intermittent usage of air is required (like fly ash handling). The Air compressor consumes 60% of the rated Power during unloading period, which may be effectively used by increasing the percentage of loading time.

32 Innovative Project #3 STOPPAGE OF LMCD FILTRATE PUMP BACKGROUND OF THE PROJECT: Lime mud claridisc filter (LMCD) is used to dewater lime slurry before it is fed to Rotary Lime Kiln. LMCD is in 16m floor.filtrate separated from lime slurry is collected in a seal tank located in ground floor. From this tank filtrate is pumped to lime mud washer using a pump of capacity 18 KW. Now the filtrate seal tank is shifted above lime mud washer and the filtrate flows directly to lime mud washer by gravity and now the pump is stopped. Power savings per annum: KWH Total cost savings per annum :4.4 Lakhs

33 Innovative Project #3 STOPPAGE OF LMCD FILTRATE PUMP BEFORE MODIFICATION AFTER MODIFICATION

34 Innovative Project #3 STOPPAGE OF LMCD FILTRATE PUMP BEFORE MODIFICATION AFTER MODIFICATION AFTER FILTERATE TRANSFER PUMP FILTERATE SEAL TANK NEW FILTERATE SEAL TANK

35 CERTIFICATES

36 CERTIFICATES

37 AWARDS & ACCOLADES S.No. Description of Awards Year Given by 1 Most Innovative Project for the Environmental Best Practices Award 2018 CII 2 Fly ash utilisation award 2018 under Green building Material-Cement Water Stewardship Award Dun & Bradstreet Corporate Award Corporate Governance and Sustainability Vision Award 2016 Mission Energy Foundation Indian Chamber of Commerce Dun & Bradstreet - Mumbai ICC -Indian Chamber of Commerce 6 IPMA Paper Mill of the year Award IPMA 7 Green Co Best Practices Gold Award 2015 CII

38 AWARDS & ACCOLADES