CII National Award for Excellence in Energy Management ITC Limited, PSPD, Unit - Kovai

Transcription

1 CII National Award for Excellence in Energy Management ITC Limited, PSPD, Unit - Kovai

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 Under GREEN POLICY, ITC Kovai is committed to monitor and improve our efforts for a cleaner environment and a better future for everyone CII Excellent Energy Efficient Unit 2010, 14, 15

3 Sheeters Water from River Sp. Water: 9.8 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 & Temsec ETP Steam Dryers, MG, Calender Board machine Coater Treated Effluent for Irrigation Sp. Power: 588 Units/T Rewinder Reel & Rewinder TSS <30ppm Finishing House Sp. Discharge = 5.5 m3/ MT D e s p a t c h

4 Mill Overall Energy Balance HP Steam Q=43.4 TPH TG 8 MW 5 MW 2.5 MW Windmill 7.5MW Stock Preparation 222 kwh/ ton LP Ext Q=29.8 TPH MP Bleed Q=5.6 TPH To condenser Q = 8TPH Deaerator Q = 6TPH Board M/C Q = 21TPH VAM Q =0.3TPH Stock prep Q = 2.5TPH Board Machine & CCK 229 kwh/ton Utilities 91.4 kwh/ ton Finishing house 10.3 kwh/ ton HVAC & Lighting 7.1 kwh / ton Intake pump house 5.2 kwh /ton Thermo compressor Q=2.4TPH Air tunnels Q=3.2TPH

5 Specific Power (kwh/mt of FNP) % Reduction

6 Specific Steam (MT/MT of FNP) % Reduction

7 Cycle 1 - PAT Performance (MTOE/T) Baseline Target

8 Unit Kovai Power Source (%) 100% 80% 60% 40% Cogen Biomass Windmill Cogen fossil State EB % 0% % Power Source was Renewable in % Saw Dust 27% CO4 Saw Dust DOB Charcoal Powder Bio-fuels in Comparison Bio-fuels in

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

10 Past Scenario : Innovative Project 1 (Internal EnCon idea) Replacement of traditional Starch Agitators with Efficient One Coating Kitchen Starch Preparation Agitators were installed in 1995 & it was operating with 30KW motor. It was not looked as Energy Saving Potential Equipment for last so many years. Present Scenario: Through technology advancement, we were able to identify a suitable agitator which can reduce power consumption by 97%. Before After Equip KW KW Starch Tank 2 Agitator Energy savings 425 Units/Day Investment 3.5 Lakhs Payback 6 Months 97% Reduction Modified Design

11 Innovative Project 2 (Internal EnCon idea) Replacement of 52 Nos MH Lamp with 18Nos Plasma Past Scenario : In our Finishing House & Godown, we were using 52Nos of 250W Metal halide Lamps for internal lighting. MH lamps are in efficient & it also requires lot of Maintenance. One team use to work continuously for lighting maintenance. Present Scenario: LEP (Light Emitting Plasma) lamps were installed in Himast and technology was explored for Hibay lamps. We were able to reduce 52Nos of MH light fittings with 18Nos 260W Plasma lamps. Energy Savings 70% Its maintenance free also. Project Summary: Energy Savings 131 Units/Day Investment 11.7 Lakhs Payback 5.4 Years

12 CO2 Emission Reduction 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: 75K MT ( ) Utilization of renewable Windmill Power for Production Plant Details 1.5MW X 5 Nos = 7.5MW Windmill 200 Lac Units Generation Potential / Annum

13 Energy Efficient Agitators & Aerator Title of Energy Saving project implemented Year of Impleme ntation Annual Energy savings (Lakh Units) Total Annual Savings Rs Lakhs Invest. Made Rs Lakhs Payback months Energy Saving Agitator for FL Blend Chest Energy Saving Agitator for FL HD TOWER Energy Efficient Aerators for ETP Total Energy Efficient Lighting & Motor Replacement of 150 Office Lights with 36W LED Energy Efficient IE3 Motor for Mini Press Total

14 Energy Efficient Pumps (Part 1) Title of Energy Saving project implemented Year of Impleme ntation Annual Energy savings (Lakh Units) Total Annual Savings Rs Lakhs Invest. Made Rs Lakhs Payback months Energy Efficient Makeup water pump Energy Efficient Recovery fibre chest pump Energy Efficient Vac Cooling Tower pump Energy Efficient Process Cooling water Pump Energy Efficient Vacuum hot well pump Energy Efficient Krofta Feed Pump Energy Efficient New SS Tank Feed Pump

15 Energy Efficient Pumps (Cont) Title of Energy Saving project implemented Year of Impleme ntation Annual Energy savings (Lakh Units) Total Annual Savings Rs Lakhs Invest. Made Rs Lakhs Payback months Energy Efficient Recovered Fiber pump Energy Efficient Krofta High Pr Pump Energy Efficient CPU Feed Pump UTY Energy Efficient UF Feed Pump_Uty Energy Efficient RO transfer pump Total

16 VFD Applications Title of Energy Saving project implemented Year of Impleme ntation Annual Energy savings (Lakh Units) Total Annual Savings Rs Lakhs Invest. Made Rs Lakhs Payback months VFD for Chest no 12 & VFD for Chest no 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 DM2 agitator Total

17 List of Major ENCON efforts planned for the next 3 years S No 8Energy Conservation Action Plan Electrical (Units/Annum) Thermal Savings (Ton of Coal/ Annum) Lakh Savings / Annum 1 Recovering Bio gas from MLSS & canteen waste Efficient Vacuum Pumps Energy conservation Schemes Fuel Shed Replacement of inefficient traditional agitators with energy efficient agitators for pulp storage chest Replacement of old pumps with new higher efficiency pumps at identified locations Installation of Variable Frequency Drives for various equipments Steam system optimisation

18 Waste Management ETP Water TNPCB Norm 1600 TDS CPCB Norm revised TNPCB Norm 150 CPCB Norm revised 131 COD BOD TSS TNPCB Norm CPCB Norm revised TNPCB Norm CPCB Norm revised 18

19 Utilization of Waste Material ETP Sludge 100% sludge generated is reused in process Process Plastics Waste 100% sent to cement plants to Co-process in kiln Fly Ash 100% fly ash generated sent to recycled for fly ash brick making

20 Energy Conservation Projects Generation TPM (Lean Manufacturing) - Kaizen - Focused Improvement Projects Energy cell - Internal Audits (By Energy cell members) - External Audits (By Third Party) - Campaigns

21 ENERGY MANAGEMENT CELL KPOV s ) Targets Power Reduction: 61 units/ Tonne of FNP Steam Reduction: 0.36 Tonne/ Tonne of FNP 2) Energy Audits planned for : Vacuum system Audit 3) Identification of one Encon Project per month and co-ordination for implementation. 4) Knowledge sharing on energy conservation Minimum two per month Energy Cell Members & Role S No Name Specialist Area of focus 1 R Muralidaran Energy Manager Overall 2 P Premaguru Utility AET- Process Specialist Water 3 D Ranjith Kumar Stock Preparation AET- Engg Specialist Power 4 V Abinesh Stock Preparation AET- Eng Specialist Power & Steam 5 TK Jegadish Board Machine AET- Process Specialist Power & Steam 6 Jasper Devapaul Board Machine AET- Engg Specialist Power & Steam 7 N Vijayakumar Finishing House AET - Engg Specialist Air 8 M Phaneendhra Utility AET- Engg Specialist Power

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

23 EnCon Projects implemented by Associates/ Vendors S No Title of Project Year of implementati on Name of Associate/ Vendor Energy Unit Energy consumptio n before project Energy consumpti on after project % Improve ment Encouraging & Coordinating vendors for GreenCo certification Increase in productivity of the Sheet cutter Reduction of Environmental Impact Fimakem NA NA NA na Suriya Cutting Works Fimachem kwh/ MT kwh/ Day % % 4 To Replace old motors with new IE2 motors M/s.Manorama Pradhan Paper and Board Karamadai kwh % 5 Replacement of Old Earth moving vehicle with energy efficient vehicle Coimbatore Earth Movers Liters of Diesel/ Day %

24 First Greenco Platinum rated Paper Mill in India, 2015 Safety award & 2015 Productivity Award 2013, 14 Excellent in Energy Management 2014, 15, 16 Best Environmental performance-innovative Project, 2013 CII National Award National Safety Council of India Coimbatore Productivity Council CII National Award 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 Globe of Honor for Environment,2011 AWARDS & ACHIEVEMENTS Excellent Water Efficient Unit, 2007, 08, 09, 11 Excellent Energy Management, 2010, 14, 15 National Energy Conservation Award, 2010 British Safety Council British Safety Council CII National Award CII National Award Bureau of Energy Efficiency 24

25 THANK YOU