BILT GRAPHIC PAPER PRODUCTS LIMITED

Transcription

1 Second Prize Paper & Pulp BILT GRAPHIC PAPER PRODUCTS LIMITED Unit: Ballarpur, Chandrapur (Maharashtra) Unit Profile BILT Graphics Paper Products Limited Unit-Ballarpur, India is one of largest manufacturer of uncoated wood free / Industrial grades of Paper & market Pulp. Unit Ballarpur has versatile range of products in Note Book printing, Map Litho/ publication, Azure Laid, Industrial packaging & industrial tissue. Unit Ballarpur has paper machines in capacity ranging from 25 TPD to 520 TPD. Unit Ballarpur started operation in the year 1953 with 25 TPD single machines. After commissioning of new PM-7 by Allimand, France with a capacity of 520 TPD in the year 2009, the installed capacity of the unit increased to 2,99,550 MT/annum. This unit is pioneer in the manufacture of wide range of high quality writing / printing & industrial grades of paper for the wide range of prestigious end users since last 62 years. In the year 2013, new Pulp mill of 900 TPD was commissioned having latest technology like continuous digester, ODL process technology with ECF Bleaching to sustain and have an edge in the market in terms of environment, energy and quality. Simultaneously India's largest Soda Recovery Boiler with capacity of 1650 TPD solid firing was commissioned. 237

2 BILT is the 1st integrated Pulp & Paper industry in India to have commissioned DAF and along with MBBR which are patented technology from Ovivo Finland to enhance environmental performance along with Pulp Mill modernization. With expansion activities undertaken as above in last 4 years, Unit Ballarpur is now one of the largest integrated Pulp & Paper manufacturers with 7 Paper machine lines and captive Pulp production facility which also caters to Pulp requirement of sister concern at Ashti & Bhigwan. Company is also in process to increase the speed of PM-7 from 1100 MPM to 1250 MPM with corresponding increase in product from 520 to 590 TPD, which will give further advantage in Energy Efficiency with further reduction in specific power and steam consumptions. To retain leadership in paper manufacturing, Unit Ballarpur have plans to scale up manufacturing capacity to 6,50,000 TPA with addition of new paper machine line having capacity of 3,50,000 MT/annum in near future which will further enhance operating efficiencies, specific energy consumption norms & also bring down fixed/ variable cost to bench mark with international level. Unit Ballarpur is 1st integrated Pulp & Paper industry in the country to implement and certified ISO Energy Management system. Unit Ballarpur is also ISO 9001, 14001, & FSC-COC & CW certified unit to ensure effective Quality, environment, safety & authenticated sourcing of Raw Material. Unit Ballarpur is focused on Triple Bottom Line concept which also pays attention to the CSR activities in and around Ballarpur area along with Environment & Economy. Unit has received several National & State level Awards for Energy Conservation, Environment Management and best safety practices. Specific Energy Consumption In last few years, there was continuous decline in Specific energy consumption due to regular improvement & implementation of energy conservation ideas in the unit carried out with active participation of employees under the umbrella of ISO Energy Management System. Despite addition of environmental compliant project like Limekiln, ODL Plant, MBBR & DAF, change in furnish, shift in production portfolio to lower GSM which is as low as 47 GSM, addition of Synchro sheeter, Wrapmatic machine for superior finished product quality, there has been drastic reduction in Specific Energy Consumption due to optimization of newly installed 520 TPD PM-7 & Pulp Mill. 238

3 Energy & Fuel Reduction trends SEC, Power (kwh/mt) SEC, Steam (Million kcal/mt) Total Coal Consumption (MT) Power Saving Achieved (Lac kwh) Thermal Saving Achieved (Million kcal) 239

4 Energy Conservation Measures for the year With implementation of following Energy Conservation initiatives implemented during with total investment of Rs. 389 Lacs has yielded into annualized monetary benefits of Rs Lacs. Major initiatives implemented are described below. Project No. 1: Coal saving due to highly efficient CFBC boiler with 86% efficiency in place of travelling grate boiler of 76% efficiency & stoppage of two travelling grate boilers. Resulting saving of 294 kw. Earlier plant had in operation 4 no's of travelling grate coal fired boilers operating at 36 Bar pressure. With commissioning of NFL,1 no. Soda Recovery Boiler & 1 no. of CFBC boiler had been put in Bar steam pressure & optimized to full capacity. CFBC boiler has operational efficiency of 86% against 76% of travelling grate. The steam requirement of the mill can now be met completely through CFBC & New Recovery boiler. Thus shutting down 2 nos. of travelling grate boilers, resulting saving in power 294 kw & coal Ton achieved by efficiency improvement Total Investment = Rs.30 Lac & Power Rs 3.10/kWh = Rs Lac / Annum Coal Savings Rs / MT = Rs. 874 Lac/ Annum Project No.2: Improved machine efficiency through operational excellence, pulp treatment & less breakdowns. With the operation excellence, innovative energy saving ideas like VFD's thermal insulations & steam traps, enhanced use of in-house pulp resulted in better run ability and efficiency. The overall pulp requirement per ton of Paper came 240

5 down to 73% from 76 % in previous year, also with increased ash content thereby consuming less Pulping energy. Total energy saving is Lac kwh/ Annum. Total Investment: Rs. 30 Lac & Power Rs 3.10/kWh = 179 Lac/ Annum Project No.3: Optimization of Energy Consumption in New Fiber Line (NFL) with increased uptime, reduction in quality rejection and improved production. New fiber line started in July, 13 with the Bld. Pulp Production of 400 TPD. With operational excellence, installation of VFD's & control valves, small modifications in the process resulted in achieving bld. Production of 600 TPD.SPC reduced from 820 kwh/t to 797 kwh/t.net power saving on higher production base of Ton was Lac kwh / Total Investment:80 Lac & Power Rs 3.10/kWh=137 Lac/Annum Project No.4: Optimization of Fresh water consumption resulting saving in pumping energy by220 kw Earlier the energy required to pump the water from River to consumption points via pump house to meet process requirement was 1330 kkw. With the brain storming, team work, piping modifications, pressure optimization & arresting leakages; the requirement of the water to manufacture paper was reduced from 89 M3/ Ton to 50 M3/ Ton. With these2 No. of Fresh water Pumps in Pump House & one at river intake having running kw of 220 kw were stopped. Total energy for water pumping reduced from 1330 kw to 1109 kw. Achieved energy saving of Lac kwh/ Annum. Total Investment: NIL & Power Rs 3.10/kWh = Lac/Annum 241

6 Project No.5: Reduction of self power consumption by shutting down of PP-1 turbine (7.5MW) Earlier Power and steam demand of the Mills were managed by 3 TG of 7.5MW, 12.5 MW & 40MW. With intensive discussion with plant technical team, decision was taken to shut 7.5 MW 36 Bar. By transferring its Power/extraction steam generation to 12.5 & 40 MW 64 Bar. By modifications in steam, Power distribution & optimizing loading of 40 MW TG,7.5 MW TG was shut. Savings on account of self power of 7.5 MW TG was 207 kw. Total Investment: Rs.25 Lac & Power Rs 3.10/KWH = 50.6 Lac/ Annum Energy Policy 242