GreenCo Best Practices Award

GreenCo Best Practices Award

TNPL Briefly World s largest bagassebased paper plant Promoted by Govt. of Tamil Nadu in early 80 s Presently produces 4,00,000 MT/year of PWP and largest exporter of PWP ISO 14001:2004, ISO 9001:2008, ISO 27001:2013and FSC FM/COC & CW/COC Certified Installed Wind Power Capacity 35.5 MW & Solar Power Capacity 6 KW reducing 45,000 tco 2 e GHG Emission Reuse lime sludge and fly ash to produce TNPL CEMENT first of its kind in pulp and paper industry Treated wastewater is used to irrigate 1660 acres by 430 farmers 25,000 m3/day biogasgenerated from bagassewash water and used in Lime kiln resulting 15 KL F. Oil saving 1,12,865 acres Pulpwood plantation since 2004 involving 22,215 farmers Four registered CDM project reduces 2.1 LakhMT CO 2 emission 200 TPD Precipitated Calcium Carbonate (PCC) Plant and 120 TPD Wet Ground Calcium Carbonate (WGCC) Plant Commissioned New Greenfield 600TPD paper board plant TNPL 2

GreenCoJourney Programme Date of Completion Feasibility study Nov 2014 Feasibility study report Nov 2014 Formation of GreenCo Cross Functional Team Members Dec 2014 Training & Handholding Visit 1 Feb 2015 Submission of first draft documents to CII for review Mar 2015 Handholding Visit 2 Apr 2015 Submission of completed documents to CII for review Apr 2015 GreenCoFinal Assessment Gold Standard @ GreenCoSummit 2015 26 th & 27 th May 2015 25th June 2015

DIP CBP HW CRP 3 P/Mc Utilities (Energy, WTP and ETP

Project No 1 LIME SLUDGE AND FLYASH MANAGEMENT (LSFM) SYSTEM WASTE TO WEALTH

Methodology Adopted Cement Lime sludge from 1 st Stage caustisizing Fly Ash Major Inorganic Solid waste

Expansion Capacity : 900 Tons/ day Lime sludge from SRP 200 T/day Fly Ash from boilers 100 T/day Capital Outlay Rs 166 Cr ( 136 +30 ) Initial Capacity : 600 Tons/ day Lime stone

Trigger major thrust/reason behind initiating the project Environmentally and Economically effective disposal & management of Solid Waste (Lime Sludge and Fly Ash) and conversion of waste to wealth

Uniqueness of the Project Conventional wood based mills follow single stage caustizising and entire lime sludge is reused. Agro based raw material contains relatively high silica content when compared to wood. Silica being one of the major non process element creates various problems, such as, high viscosity, corrosion, low energy generation, evaporator & boiler tube plugging and scaling in chemical recovery cycle. Hence, two stage caustizisingprocess is necessary to purge part of silica entering to chemical recovery cycle to avoid silica build-up in the system. Lime sludge purged from the first stage caustizisingis the one of the major inorganic solid waste and it is unique problem to agro based mills

Uniqueness of the Project H 2 O Green Liquor (Na 2 S + Na 2 CO 3 100% Ca(OH) 2 Caustizising(Na 2 S + Lime Kiln CaO+ CO 2 Ca CO 3 2NaOH + Ca CO 3 White Liquor (Na 2 S + 2NaOH) Reused in the digester Conventional wood based Process

Uniqueness of the Project Green Liquor (Na 2 S + Na 2 CO 3 30% Ca(OH) 2 1 st Stage Caustizising(Na 2 S + H 2 O 2NaOH + Na 2 CO 3 + Ca CO 3 70% Ca(OH) 2 Lime Kiln CaO+ CO 2 Ca CO 3 2 nd Stage Caustizising(Na 2 S + 2NaOH + Ca CO 3 White Liquor (Na 2 S + 2NaOH) Ca CO 3 With high silica solid waste Non-Conventional agro based Process

Technological Challenges 1. Raw Material blending: Density of Lime Sludge & Stone: Optimized by various combination of Sludge and Stone ratio as NO reference is available 2. High sodium content in the sludge Introduction of additional washer for sludge washing reduced sodium content in sludge 3. Drying the sludge to 1% moisture by drum washer and then by hot air Hot air generated from pre heater is used for drying 4. Variation of LOI in the fly ash due to variations in the pith use in Power. Mixed with Low LOI fly ash from other boilers where pith is not used

Maintenance Challenges 1. Frequent change of bag filter due to damage No previous experience in bag filter maintenance. Periodical inspection and proper maintenance eliminated the issue 2. Transportation of lime sludge for about 3 km through pipeline Jamming of pipe line reduced by reduced consistency and line flushing before and after pumping.

Administrative Challenges Mini Cement Mill: Experience personnel are not available for Production as well as Quality Control Personnel from Paper Mill is transfer to Cement Mill Marketing of Product : Initially it is sluggish as Cement is manufactured from Waste. Product Quality is ensured by Strict Quality Control department and Market is captured.

Replication potential of the project in Indian Industry All the agro based integrated pulp and paper industry will have similar issue of silica build-up in the chemical recovery cycle and generation of inorganic solid waste from the first stage To avoid silica built-up and solid waste issue and to utilize the fly ash they can adopt this innovative approach.

Pay Back Parameter Unit Value Investment made for 600 TPD Rs in million 1,360 Investment made for expansion to 900 TPD Rs in million 300 Total investment Rs in million 1,660 Annual savings for 900 TPD Rs in million 400 Payback period month 50

Tangible & Intangible Benefits Parameter Unit Value 2013-14 2014-15 2015-16 Cement Production MT 1,13,904 1,61,910 1,96,572 Solid waste elimination due to reuse of Lime sludge Solid waste elimination due to reuse of Flyash MT 62,631 85,203 78,570 MT 20,839 29,621 45,074 Conserved Lime Stone MT 40,418 54,894 50,704 GHG emission reduction due to lime stone conservation t CO2 e 17,784 24,193 22,310

Tangible & Intangible Benefits Parameter GHG emission reduction due to logistic reduction of lime sludge GHG emission reduction due to logistic reduction of fly ash Reduction fuel saving due to logistics reduction Total GHG emission reduction due to LSFM Unit Value 2013-14 2014-15 2015-16 t CO 2 e 470 639 589 t CO2 e 156 222 121 KL 208 287 236 t CO2 e 18,410 25,054 23,020

Project 2 REDUCE BLACK LIQUOR CONTENT IN HARDWOOD FINE REJECTS TO UTILIZE AS FUEL IN POWER BOILER.

Methodology Adopted Recover BL to recovery boiler Hardwood Digester Screen Rejects Stored in bagasse yard Screw Press To effluent Twin Roll Press Unbleached pulp for bleaching Recovered fines send to boiler(fuel) Before Project Knotters Knots Reused in the digester After Project

Trigger major thrust/reason behind initiating the project Reduction & effective management of disposal solid waste (Hard wood rejects) with black liquor content under the concept of waste to energy

Uniqueness of the Project Designed and implemented internally to reduce the pollution load to generate energy from waste & conserve the resources.

Technological & Maintenance Challenges Screw press was designed in-house and also there was no reference data available for this process, therefore initially many trials were conducted to optimize the inlet and outlet consistency of the sludge for trouble free operation

Replication Potential of the Project in Indian Industry Can be Replicated in all the wood based integrated pulp and Paper Industry

Spinoff Project Enquires are coming from kraftpaper mills to use this material as fibre source. If it is successful, it will give additional economic value than using it as fuel in the boiler.

Tangible & Intangible Benefits Parameter Unit Value Utilization of fine rejects in the boiler as a fuel per annum Mt 1,116 Thermal energy saved per annum GJ 7,704 Saving per annum by utilization Hardwood fine rejects as fuel Rs in lakh 19.2 Alkali reused per annum Kg 82,814 Saving per year utilization Hardwood fine rejects as alkali reused Rs in lakh 7.7 Black liquor avoided to Effluent m 3 9,900 Saving per annum by utilization of Hardwood fine rejects as black liquor recovery Rs in lakh 29.6 Emission reduction per annum t CO 2 e 1,619 Total saving per annum by utilization Hardwood fine rejects Rs in lakh 56.5

Pay Back Parameter Unit Value Investment made Rs in lakh 15 Annual savings achieved Rs in lakh 56.5 Payback period month 3

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