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CENTURY PULP AND PAPER LALKUA, NAINITAL ( A BK BIRLA GROUP OF

CENTURY PULP AND PAPER LALKUA, NAINITAL ( A BK BIRLA GROUP OF COMPANY ) ISO –9001 – 2000 AND ISO -14001 CERTIFIED COM PANY . AN INTEGERATED PULP & PAPER UNIT 31320 TPA RAYON GRADE UNIT

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CENTURY PULP AND PAPER LALKUA, NAINITAL ( A BK BIRLA GROUP OF

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  1. CENTURY PULP AND PAPER LALKUA, NAINITAL ( A BK BIRLA GROUP OF COMPANY ) ISO –9001 – 2000 AND ISO -14001 CERTIFIED COM PANY • AN INTEGERATED PULP & PAPER UNIT • 31320 TPA RAYON GRADE UNIT • 37250 TPA WOOD BASE WRITING PAPER • 84600 TPA BAGASSE BASE PAPER ECO MARKED BAGASSE PAPER

  2. CENTURY PULP AND PAPER POWER ARRANGEMENTS • 6.8 MW TG SET • 21 MW TG SET • 7.5 MVA CONTRACT DEMAND FROM • UPCL 6,10,000 UNITS /DAY

  3. CENTURY PULP AND PAPER THERMAL ENERGY ARRANGEMENTS 23 TPH 46 Kg/cm2FBC C F B 3 NO 25 TPH 46 Kg/cm2 SPREADER STOCKER CFB 1 NO 50 TPH 62 Kg/cm2 FBC C F B 2 NO 40 TPH 46Kg/cm2 CHEM REC BOILER( BHEL ) 1 NO 50 TPH 62Kg/cm2 CHEM REC BOILER( ABL ) 1 NO

  4. ELECTRICAL ENERGY (KWH) : 2001 - 2004

  5. ELECTRICITY CONSUMPTION AND COST • 2001-02 2002-03 2003-04 • PURCHASED • UNITS (Lac kwh/yr) 239.83 192.27 159.73 • COST ( Rs lacs/yr) 1399 1177.84 746.84 • OWN GENERATION • THROUGH DG SETS • UNITS (Lac kwh/yr) 47 34.81 19.37 • COST ( Rs lacs/yr ) 219.44 182.88 117.13 • THROUGH STEAM TURBINES • UNITS ( Lac kwh/yr) 1754.58 1865.88 2001.13 • COST ( Rs lacs/yr) 1937.58 1974.96 1903.86

  6. TOTAL CONSUMPTION OF ELECTRICITY 2001-02 2002-03 2003-04 UNITS (Lac kwh/yr ) 2041.41 2092.96 2180.23 COST (Rs lac/yr) 3556.02 3335.68 2767.83

  7. THERMAL ENERGY CONSUMPTION FOR PROCESS • 2001-02 2002-03 2003-04 • COAL • HEAT VALUE (Mkcal/yr) 728037 653007.6 651336.7 • BLACK LIQUOR • HEAT VALUE 659445 704815 711616.75 • PITH • HEAT VALUE 60501 78867 74641.5 • TOTAL 1447983 1436690 1437595

  8. APPROACH FOR ENERGY CONSERVATION • AWARENESS – EDUCATION & TRAINING • CAPACITY UTILIZATION INCREASED • OPTIMIZATION OF VOLTAGE • OPTIMIZATION OF FREQUENCY • OPTIMIZATION OF OPERATING PROCEDURES • THRUST ON RECYCLE & WASTE MINIMIZATION • FINE TUNING OF PLANTS & EQUIPMENTS • INSTALLATION OF VFD”S • ADOPT ENERGY EFFICIENT LIGHTING • USE OF EFFICIENT EQUIPMENT • TECHNOLOGY UPGRADATION • ASSESSMENT AND MONITORING

  9. ASSESSMENT & MONITORING • AUDIT CONDUCTED BY CII : APRIL2003 • 39 ENERGY SAVING SCHEMES IDENTIFIED • AUDIT CONDUCTED BY INGERSOLL RAND : SEPT 2003 • 8 SCHEMES IDENTIFIED • AUDIT CONDUCTED BY ECKO PUMPS FOR PAPER • M/C III VACUUM SYSTEM : OCT2004 • 4 SCHEMES IDENTIFIED • AUDIT CONDUCTED BY DSCL FOR ENERGY COST • REDUCTION IN FEB 2004 : 4 SCHEMES IDENTIFIED • MOTOR EFFICIENCY ASSESSMENT BY VBI SYSTEMS • PLANT TECHNICAL AUDITS BY INDEPENDENT • COUNSULTANTS : AUG 2004

  10. ORGANISATIONAL SET UP FOR ENERGY CONSERVATION PRESIDENT EC CELL LOSS IDN COM ISO 14001/ ISO 9001/QC TPM * PRODUCTION * TPM SEC * 3 MEMBERS * MR. * POWER HOUSE * PILAARS * CROSS FUNCT * SYSTEM COORD. TEAMS * ELECT&INST * OVERLAPPING * QUALITY CIRC COMMITTEES * ENV & WATER * STO & PUR * PURTA

  11. ENERGY CONSERVATION CELL • FUNCTIONS • COORDINATE STEAM & POWER REQUIREMENTS • STUDY VARIANCE • IDENTIFY ENERGY CONSERVATION OPPURTUNITIES • REVIEW ENERGY AUDIT FINDINGS • STRATEGY • INCREASE AWARENESS • ACHIEVE MAXIMUM PLANT EFFICIENCY • INDUCT LATEST TECHNOLOGY • ENSURE TIME BOUND IMPLEMENTATION

  12. TPM A ZERO BASED APPROACH ENHANCE PLANT EFFICIENCY

  13. ZERO BASED APPROACH LOSS FAILURE DEFECT DOUBT ACCIDENT BREAKDOWN 0

  14. AUTONOMOUS MAINTENANCE( JISHU HOZEN ) MY MACHINE I MAINTAIN

  15. EDUCATION AND TRAINING • SKILL DEVELOPMENT : TRAINING PROGRAMME • TPM AWARENESS 118 • TECHNICAL 722 • BEHAVIORAL 99 • FIRE AND SAFETY 209 • ON JOB TRAINING THROUGH ONE-POINT-LESSON SHEET

  16. TPM RE- DEFINED TOTAL POSITIVE MIND TOTAL POSITIVE MIND TOTAL POSITIVE MIND

  17. LOSS IDENTIFICATION COMMITTEE • HIGHLIGHT PROCESS INEFFICIENCIES • CHECK LOSSES OF ALKALI,FIBRE,WATER, CHEMICAL AND STEAM • ARRANGE CORRECTIVE MEASURES

  18. ISO 9001-2000 • CONTINUAL IMPROVEMENT • WASTE MINIMIZATION • ISO14001 • CONSERVATION OF RESOURSES • ADOPTING CLEANER TECHNOLOGIES • ALTERNATIVE FIBRE RESOURSES • UTILIZATION OF WASTE LIME MUD • UTILIZATION OF WASTE PITH QUALITY CIRCLE • 19 CIRCLES OPERATIVE

  19. ONLY MENTAL ENERGY ANNUAL SAVING IN POWER UTILISATIONWITHOUT INVESTMENT

  20. NO / LOW INVESTMENT SCHEME 2001-02 2002-03 2003-04 NO OF SCHEMES 2 8 9 SAVINGS / ANNUM KWH (LACS) 11.82 8.914 36.755 COAL EQ (TONS) - 16366 32550 Rs ( LACS) 24.65 312.45 658.64 INVESTMENT 2.11 - - TOTAL Rs 995.74

  21. ENERGY CONSERVATION SCHEMES NO / LOW INVESTMENT ( 2001 – 02)

  22. ENERGY CONSERVATION SCHEMES NO / LOW INVESTMENT ( 2002 – 03)

  23. NO / LOW INVESTMENT ( 2002 – 03)

  24. NO / LOW INVESTMENT ( 2002 – 03)

  25. NO / LOW INVESTMENT ( 2003 – 04)

  26. VARIABLE FREQUENCY DRIVES

  27. ENERGY CONSERVATION SCHEMES • VFD2001-02 2002- 03 2003-04 TOTAL NOS INSTALLED 16 11 25 • INVESTMENT 39.3 8.06 31.03 • SAVINGS /ANNUM • KWH (LACS) 21.2 3.66 11.36 • Rs (LACS) 42.4 8.22 22.72 73 . 34 LACS UNIT COST Rs 2.00

  28. VFD - FANS, BLOWERS & PUMPS AFFINITY LAWS Q1 = N1 Q2 N2 2 P1 = N1 P2 N2 3 HP1 = N1 HP2 N2 P2 P mtr of wc P1 Q1 Q2 Q(LPM)

  29. THROTTLING VS SPEED CONTROL

  30. POWER REQUIREMENT VSD VS VALVE THROTTLING • A- damper control = • 0.4 +0.6Q • B -VSD control = Q3 • ASSUMPTIONS : • Static Head on fan/ • pump is negligible. • Fan/pump input is 0.4 • Per Unit under full • valve/ damper • closed condition. 100 A Fan/ Pump Input Power 80 60 40 20 B .2 .4 .6 .8 1.0 Q(LPM) Per unit flow discharge

  31. ENERGY CONSERVATION SCHEMES ELECTRICAL VFD (2001-02)

  32. ELECTRICAL VFD (2002-03)

  33. ELECTRICAL VFD (2003-04)

  34. ELECTRICAL VFD (2003-04)

  35. SLD BAGASSE PAPER M/C

  36. SLD BAGASSE PULP

  37. SLD RGP MCS

  38. SLD WPP CCS ETP TR 3

  39. 132/11 KV 10MVA 11/11KV TG 2 21 MW TG 1 6.8MW BPULP B M/C RGP WPP

  40. HARMONICS STUDY FINDINGS TG1 TG2 DG GR TR 1 GR TR 2 Vthd 1.93 3.80 2.98 0.72 1.78 Ithd 3.52 3.63 3.42 1.17 1.78 PERMITTED VALUES 5 %

  41. OTHER ELECTRICAL SCHEMES FOLLOWED: • PROVISION OF LOAD TRANSFER FROM GRID TO TG WITHOUT INTERRUPTION TO UTILIZE SOURCES • PREVENT IDLE RUNNING OF EQUIPMENTS BY • INTERLOCKING OF PUMPS & AGITATORS • EFFECTIVE CONTROLS LIKE ONE PB FOR COMPLETE GROUP EQUIPMENTS OF PLANT • SWITCH OFF EQUIPMENTS THROUGH TIMERS • DELTA - STAR FOR LIGHTLY LOADED MOTORS • NEUTRAL COMPENSATORS FOR UNBALANCE LOADS • LED”S FOR INDICATING LIGHTS • LOW LOSS HRC FUSES • USE OF ENERGY SAVERS FOR LIGHTING CIRCUITS • USE OF PHOTO CELLS FOR STREET LIGHTS • SPLITTING OF CIRCUITS FOR BETTER CONTROL

  42. TOTAL SAVINGS / ANNUM ( FOR LAST THREE YEARS) KWH (LACS) 4.62 Rs (LACS) 9.24 INVESTMENT Rs (LACS) 9.65

  43. ENERGY CONSERVATION SCHEMES ELECTRICAL OTHERS

  44. ENERGY CONSERVATION SCHEMES ELECTRICAL OTHERS

  45. TOTAL SAVINGS THERMAL / PROCESS 2001-02 2002-03 2003-04 INVESTMENT 77.55 78.90 853.79 SAVINGS KWH (LACS) 29.02 27.69 19.73 COAL EQ.(TONS) 6765.7 5500 3593 Rs (LACS) 235.48 160.58 574.46 970.52 KWH = Rs 2.00 COAL/TON = Rs1800

  46. ENERGY CONSERVATION SCHEMES THERMAL / PROCESS 2001 - 02

  47. THERMAL / PROCESS 2001 – 02 contd…

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