Presentation on Excellence in Energy Management-2017
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1 Presentation on Excellence in Energy Management-2017
2 Company Profile Kuantum Papers is in the business of production and marketing of writing & printing paper, while conserving precious resources & protecting the environment.the mill was established in , in a village - Saila Khurd, in District Hoshiarpur, in the state of Punjab, India, with an aim to utilize wild Agro vegetations like Sarkanda Grass and Kahi Grass, and Agro-residues such as Wheat straw and Bagasse, to make writing and printing grades of paper. These Agro vegetations were at the time being burnt in the fields, leading to environmental pollution. Thus by creating an application for their use, we helped reduce environmental degradation substantially. It has now reached a level of TPA in paper production. The company employs approximately 1400 people, and the annual sales turnover touches Rs million.
3 Plant Equipment Details:- Utility Details Boiler Section Power Section Boiler TPH 35 Kg/cm 2 TG-02 5 MW Condensate Boiler TPH 35 Kg/cm 2 TG MW Back Pressure Boiler TPH 67 Kg/cm 2 TG MW Back Pressure Chemical Recovery Boiler Pulp Mill Details 21 TPH 67 Kg/cm 2 Grid S/S Supply at 66 KV 10.5 MVA Agro Section Hardwood Section Agro Street 160 TPD Hard Wood 60 TPD
4 Plant Equipment Details:- Paper Machines Other Sections Paper Machine TPD Effulent Tratment Plant 20000m 3 /day Paper Machine TPD Chemical Recovery Plant 200 TPD Paper Machine TPD Lime Kiln Plant 40 TPD Paper Machine TPD Fluidized Bed Reactor 85 TPD
5 Achievement:- In Terms of Savings ENERGY CONSERVATION PROJECTS DURING SR. NO PROJECT AREA POWER CONSUMPTION (KW) BEFORE MODIFICATION SAVING IN SAVING IN AFTER KWH (PER Rs. MODIFICATION ANNUM) MILLIONS REMARKS 1 PCC PUMP PM # Pump Impeller Trimmed. 2 BSW#0 VAT DILUTION PUMP PULP MILL HP Motor Replaced With 75HP Motor & New Energy Efficient Pump Installed. 3 BSW#1 VAT DILUTION PUMP PULP MILL HP Motor Replaced With 75HP Motor & New Energy Efficient Pump Installed. 4 BSW#2 VAT DILUTION PUMP PULP MILL HP Motor Replaced With 75HP Motor & New Energy Efficient Pump Installed. 5 BSW#3 VAT DILUTION PUMP PULP MILL HP Motor Replaced With 75HP Motor & New Energy Efficient Pump Installed. 6 DECKER WASHER CLEANING SHOWER PULP MILL HP Motor Replaced With 20 HP Motor & New Energy Efficient Pump Installed.
6 Cont In Terms of Savings ENERGY CONSERVATION PROJECTS DURING SR. NO. PROJECT AREA POWER CONSUMPTION (KW) SAVING IN SAVING IN BEFORE MODIFICATION AFTER MODIFICATION KWH (PER ANNUM) Rs. MILLIONS REMARKS 7 ALKALI WASHER CLEANING SHOWER PULP MILL HP Motor Replaced With 15 HP Motor & New Energy Efficient Pump Installed. 8 HYPO SUPPLY PUMP (AGRO) PULP MILL HP Motor Replaced With 7.5 HP Motor & New Energy Efficient Pump Installed. 9 HYPO SUPPLY PUMP (HARDWOOD) PULP MILL HP Motor Replaced With 7.5 HP Motor & New Energy Efficient Pump Installed. 10 FEED WATER PUMP POWER HOUSE VFD Installed 11 VACUUM PUMP NO.1 PM # HP Motor Replaced With 150 HP Motor & New Energy Efficient Pump Installed. 12 VACUUM PUMP NO.2 PM # HP Motor Replaced With 180 HP Motor & New Energy Efficient Pump Installed.
7 Achievement:- In Terms of Savings Sr. No. PROJECT ENERGY CONSERVATION PROJECTS DURING Area POWER CONSUMPTION (KW) BEFORE MODIFICATION AFTER MODIFICATION SAVING IN KWH (PER ANNUM) SAVING RS.millions 1 H2 TOWER AGT. PULPMILL H1 TOWER AGT. PULPMILL REMARKS 50HP/960RPM MOTOR REPLACED WITH 40HP/960RPM MOTOR 50HP/960RPM MOTOR REPLACED WITH 30HP/960RPM MOTOR 3 WASH WATER PUMP PULPMILL VFD INSTALLED 4 WHITE LIQUOR PUMP CD PULPMILL VFD INSTALLED 5 CBD BLACK LIQ. PUMP PULPMILL VFD INSTALLED 6 MC PUMP PULPMILL VFD INSTALLED 7 MC PUMP PULPMILL VFD INSTALLED 8 DILUTION PUMP PM# HP/1440RPM MOTOR REPLACED WITH 50HP/960RPM MOTOR 9 CHEST NO.40 PUMP PM# HP/1440RPM MOTOR REPLACED WITH 20HP/1440RPM MOTOR 10 CHEST NO.38 PUMP PM# HP/1440RPM MOTOR REPLACED WITH 15HP/1440RPM MOTOR 11 CHEST NO.39 PUMP PM# HP/1440RPM MOTOR REPLACED WITH 20HP/1440RPM MOTOR 12 BOOSTER PUMP PM# VFD INSTALLED
8 Cont In Terms of Savings Sr. No. PROJECT ENERGY CONSERVATION PROJECTS DURING Area POWER CONSUMPTION (KW) BEFORE MODIFICATION AFTER MODIFICATION SAVING IN KWH (PER ANNUM) SAVING RS.millions 13 BOOSTER PUMP PM# VFD INSTALLED 14 30M3 PUMP PM# VFD INSTALLED 15 15M3 PUMP PM# VFD INSTALLED 16 SCC PUMP PM# VFD INSTALLED 17 TCC Pump PM# IMPELLER TRIMMED 18 F/CHEST PUMP (CLEAR) # 60 PM# VFD INSTALLED H/W REFINED (BLEND) 19 CHEST- PUMP S/Wood REFINED CHEST- 20 PUMP HARDWOOD SPARE CHEST - 21 PUMP PM# VFD INSTALLED PM# VFD INSTALLED PM# VFD INSTALLED 22 DEFLAKER CHEST PUMP PM# VFD INSTALLED 23 CVACUUM SEAL PIT PUMP PM# VFD INSTALLED PURCHASED H/W HOLDING 24 CHEST AGITATORT (2KV) PM# REMARKS EXISTING AGITATOR REPLACED WITH NEW TECHNOLOGY AGITATOR OF NORD MAKE
9 Cont In Terms of Savings ENERGY CONSERVATION PROJECTS DURING Sr. o. PROJECT Area POWER CONSUMPTION (KW) BEFORE MODIFICATION AFTER MODIFICATION SAVING IN KWH (PER ANNUM) SAVING RS.millions REMARKS 25 COAL CRUSHER (BOILER # 4) POWER HOUSE HP 1440RPM MOTOR REPLACED WITH 50HP 960RPM 26 CEP PUMP POWER HOUSE VFD INSTALLED 27 FD FAN BOILER NO.3 POWER HOUSE VFD INSTALLED 28 SCFT PUMP CRP VFD INSTALLED 29 PLFT PUMP CRP VFD INSTALLED 30 AMT TANK TRANSFER PUMP CRP VFD INSTALLED 31 PCFT PUMP CRP VFD INSTALLED 32 COOLING TOWER PUMP CRP VFD INSTALLED GREEN LIQUOR TRANSFER 33 PP. WHITE LIQUOR TRANSFER 34 PP. CRP VFD INSTALLED CRP VFD INSTALLED
10 PROJECTS WITH NO INVESTMENT PAPER MACHINE-04 PRIMARY CENTICLEANER 11 KV DRIVEN MOTOR PUMP IMPELLER TRIMMED FOR FY Power Consumption Before Pump Impeller Trim = 709 Kw Power Consumption After Pump Impeller Trim = 518 Kw Power Consumption Saving Per Hours = 191 Kw Power Consumption Saving 15,12,720 Kwh/Annum.
11 PROJECTS WITH NO INVESTMENT PAPER MACHINE-04 TERITARY CENTICLEANER PUMP IMPELLER TRIMMED FOR FY Power Consumption Before Pump Impeller Trim = 83 Kw Power Consumption After Pump Impeller Trim = 78 Kw Power Consumption Saving Per Hours = 5 Kw Power Consumption Saving Kwh/Annum.
12 In Terms of Kwh/MT of Finished Production Description Specific Electrical Energy Consumption Kwh/MT of Finished Production Kwh/MT of Finished Production
13 In Terms of Mtoe /Finished Production Description Specific Energy Consumption Sec(Mtoe) Specific Energy Consumption Sec(Mtoe)
14 INNOVATIVE PROJECTS: USES OF BIOGAS AS A FUEL IN BOILER S FROM UPFLOW ANAROBIC SLUDGE BLANKET. CONVERSION FROM RICE STRAW TO ETHANOL BY FERMENTATION (PLANT UNDER ERECTION STAGE). BIOCLEANER TECHNOLOGY:
15 BIOCLEANER TECHNOLOGY: The company has also entered into a tripartite agreement with Department of Biotechnology, Himachal Pradesh University, Shimla and M/s Bio Cleaner, USA for implementing IMBR (Immobilized Microbial Bioreactor) technology for waste handling in various sectors including Pulp & Paper, Sludge Disposal, Sewage Treatment etc. Implementation of IMBR technology in pulp & Paper industry for liquefaction of waste activated sludge for addressing the problem of secondary sludge disposal with minimal power consumption and demonstration of IMBR technology for Sewage treatment at Municipal Corporation Shimla, are the key achievements of the Company in this area of Environmental Research.
16 BIOCLEANER TECHNOLOGY:
17 Team Work in ENCON: Steering Committee MD & Senior Leadership Guiding Panel Champions Technical Head Process Head Area Improvement Team Department Heads, Executives and service department members
18 KAIZEN SCHEME: Kuantum Papers has achieved benefits of rupees worth 42.7 million INR through Kaizen scheme. Kaizen Committee has been constituted who review and implement the Kaizens submitted by the employees. 28 teams across 8 sections in the Paper mill has been constituted No of Kaizen Submitted is 234 in
19 UTILIZATION OF MILL WASTE: Kuantum Papers Limited also uses the mill waste as a fuel in boilers for environment cleaning. WOOD CHIPS DUST. PITH. STRAW DUST. Utilization of ETP sludge for board making. Boiler Fly ash for bricks making.
20 Renewable Energy: CELLULOSIC ETHANOL PROJECT: Company has also been granted a prestigious project from BIRAC, Department of Bio-Technology, GOI titled, Cellulosic ethanol pilot plant for rice straw management worth Rs Crores for demonstration of patented technology acquired by the company, to address the issue of paddy straw burning in open fields by the farmers leading to air pollution. This project is currently in the advanced stage of implementation and successful demonstration of this technology will provide a viable solution for various stakeholders including Punjab Pollution Control Board and Govt. of Punjab, besides contributing significantly for implementation of Ethanol Blending Programme of Govt. of India. According to an estimate, after successful demonstration of the technology currently implemented by Kuantum Papers Ltd, Punjab can alone meet the demand of 10% ethanol blending requirement of entire country by using paddy straw which is burnt in the open fields by the farmers in the absence of any viable technology.
21 Renewable Energy: CELLULOSIC ETHANOL PROJECT:
22 Renewable Energy: BIOMETHANATION OF WET WASHING EFFLUENT: Wet washing effluent generated during wet cleaning of agro-residues is treated in the biomethanation plant based on Upflow Anaerobic Sludge Blanket ( UASB Technology) for reduction in pollution load with biogas as a byproduct. The biogas generated in the UASB reactor is used as fuel in the FBC Boiler.
23 Renewable Energy: BIOMETHANATION OF WET WASHING EFFLUENT:
24 Renewable Energy: Boimethane Generation Description Units April -17 May -17 June- 17 July -17 Biomethane generation M³ LP Steam consumption in Biogas Plant MT Rice husk saving equivalent to methane gas MT Rice husk saving Rs.(Lacs)
25 Thanks...
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