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BEST ENERGY SAVING PRACTICES AT BPU

BEST ENERGY SAVING PRACTICES AT BPU. Task Force Program On Energy Conservation (Pulp & Paper Sector) Ballarpur Industries Limited Unit Ballarpur. Energy Conservation In Indian Pulp & Paper Industry. – WHY Energy Conservation ?

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BEST ENERGY SAVING PRACTICES AT BPU

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  1. BEST ENERGY SAVING PRACTICES AT BPU Task Force Program On Energy Conservation (Pulp & Paper Sector) Ballarpur Industries Limited Unit Ballarpur

  2. Energy Conservation In Indian Pulp & Paper Industry – WHY Energy Conservation ? • Energy Intensive Industry (6th largest Energy Consumer) • Increasing Trend of Energy Cost due to fossil fuel depletion (Energy Costs nearly 20% of Mfg. Cost) • Far behind in Energy Consumption norms as compared to our competitors in developed countries. • Lot of scope in the area of Energy Conservation & hence attractive option for improving profitability & growth.

  3. Success Story of Unit Ballarpur Back ground : Full Fledged Energy Conservation Cell founded in early 1980’s as per VISION of Mr LM Thapar (Chairman, Ballarpur Industries Ltd.). Objectives : • To consider Energy as one of Key and vital Input both on National and Industrial perspective • To reduce Energy Cost • Energy norms to be made component of Departmental budgets • To Reduce energy wastage by regular plant Audits • To consider new Energy efficient Technologies and equipment • To involve and motivate employees for Energy saving Proposals

  4. SET UP OF ENERGY CONSERVATION CELL DEPTT. SUB -TEAMS CHEMICAL ENGINEER (HEAD) MECHANICAL ENGINEER ELECTRICAL ENGINEER Group VP (Op.) ENERGY CELL VP / GM (Tech.) WEEKLY & MONTHLY AUDIT DATA GENERATION ENERGY CONSERVATION MEASURES (IDENTIFICATION & IMPLEMENTATION) ENERGY AWARENESS PROGRAMME DATA FEED BACK CONTROL OF SAVING ACHIEVED

  5. PAPER PRODUCTION (Lac MT)

  6. Energy Cost (% of total Manufacturing Cost) (In spite of increase in Coal & Grid Power prices)

  7. Water Consumption (kL/ MT Paper) Up to Jan-05

  8. Specific Thermal Energy Consumption

  9. Specific Electrical Energy Consumption * State art of Equipments added in Yr 2002-03 for automation in Paper cutting & finishing for Improved Quality & Customer Satisfaction

  10. Increase in Electrical Energy consumption is due to - - Additional Chlorine Dioxide Production for bleached Pulp. - Addition of new, automatic paper conversion Equipment such as Cameron, Pasaban & Wrapmatic. - Trim Blowers for broke handling at winders. - Shrink wrap bundling machine - Modern Paper Warehouse, 5520 Sq. mtr Reasons for increase in Power in 2002-03

  11. Specific Energy Consumption

  12. Paper Finishing New Equipments Pasaban Cutter 100 TPD Ream Wrapping Machine

  13. Paper Finishing New Equipments New Ware House Cameron Rewinder Shrink Bundling Machine

  14. Best Energy Saving Practices At Ballarpur Project/ Measures No. 1 Grinding of PM-3 Dryer cylinders Paper Machine No.3 Dryer cylinders had developed grooves due to which uniform drying was not taking place 24nos. Dryer cylinders were grinded by M/S Pikoteknik Finland for improving Heat transfer & paper quality which also resulted in reducing the specific steam consumption. Steam saving = 1.209 T/hr = 1.21x 24x 355 = 10309 MT /Yr Equivalent Coal = 10309 x 0.220 = 2268 MT Coal Saving in Rs. = 2268 x 1355/- = 30.73 Lacs InvestmentRs. 150 Lacs

  15. Best Energy Saving Practices At Ballarpur Project/ Measures No. 2 (a) Increasing moisture by 1.3% after grinding of PM-3 resulting saving Pulp & Steam (for drying). Fin. Prodn. Nov-03 to Mar-04 = 21080 MT Increase in moisture (3.5 to 5%) = 1.3% Saving in fibre (21080x 1.3%) = 274 MT Cost of pulp Rs/MT = 10500 Saving achieved = 274 x 10500/100000 lacs Saving in Rs. = 28.77 lacs Investment: With same investment as in Project No.1

  16. Best Energy Saving Practices At Ballarpur Project/ Measures No. 2(b) Reduce the number of steps Installation of on line QCS on PM-4 for better control of moisture & basis weight. Fiber saving achieved by increasing moisture from 2.54 to 4.4% (1.86%) Fin. Prodn. Nov-03 to Mar-04 = 4929 MT Increase in moisture (2.54 to 4.4%) = 1.86% Saving in fibre (4929 x 1.86%) = 91.67 MT Cost of pulp Rs/MT = 10500 Cost of Fibre in Rs = 91.68 x 10500/100000 Investment: Rs. 30.40 Lacs

  17. Best Energy Saving Practices At Ballarpur Project/ Measures No. 3 Installation of feed water heater in Coal Boiler no. 4 & 6 Feed water heater installed for Coal Boiler no. 4 & 6 to increase feed water temp from 105 to 135 Deg C. Saving in Coal = 9.315 MT/ Day = 3260 MT on Yearly basis Actual Coal saving in the year after installation = 9.315 x 152days = 1416 MT Cost of Coal/ MT = Rs 1355 Saving in Rs. =1416 x 1355/- = Rs. 19.19 Lacs Investment Rs. 5.00 Lacs

  18. Best Energy Saving Practices At Ballarpur Project/ Measures No. 4 Replacement of old inefficient Cl2 Compressor in CSC plant Old Cl2 compressor was having less capacity with gland type design, which has been replaced with higher capacity new design compressor with mechanical seal. It has resulted in lower power consumption Saving in Power = 11.64 x 24 x 330 = 92189 Capturability 95% = 87579 Kwh p.a. Cost of own generation = Rs. 1.20/ kWH Saving in Rs. = 1.20 x 87579/ 100000 = 1.05 Lac p.a. Investment Rs. 3.0 Lacs .

  19. Best Energy Saving Practices At Ballarpur Project/ Measures No. 5 Replacement of inefficient rotor of warm water pump in Pulp mill Presently two pumps of 300 M3/hr with 100 HP x 1450-rpm motor were running to meet the water requirement in blow heat recovery running load was 100 & 70 amps respectively. The total water requirement was 400 to 450 M3/hr. It was discussed with M & P Engr to replace only rotor (Impeller) to get the reqd capacity from existing one single pump keeping casing etc same. The rotor was ordered & replaced in Jan-04, which is meeting the water requirement with single pump & running load is 123 Amps Saving in Power = 30 kwh = 30 x 24 x 350 p.a = 252000 kwh p.a Cost of own generation = Rs. 1.20 per kwh Saving in Rs. = 252000 x 1.20 = 3.02 Lac p.a.  Investment Rs. 0.75 Lacs for one rotor.

  20. Best Energy Saving Practices At Ballarpur Project/ Measures No. 6 Replacement of In-efficient rotor of Warm water pump Presently two pumps of 300 M3/hr with 100 HP x 1450-rpm motor were running to meet the water requirement in blow heat recovery running load was 100 & 70 amps respectively. The total water requirement was 400 to 450 M3/hr. It was discussed to replace only rotor (Impeller) to get the reqd. capacity from existing one single pump keeping casing etc same. The rotor was ordered & replaced in Jan-04, which is meeting the water requirement with single pump and running load is 123 Amps Saving in Power = 252000 kwh p.a.  Cost of own generation = Rs. 1.20 per kwh Saving in Rs. = 3.02 Lac p.a. Investment Rs. 0.75 Lacs for one rotor.

  21. Best Energy Saving Practices At Ballarpur Project/ Measures No. 7 Optimising Refiner operations by running 0.5 SDM in place of 0 SDM on PM-6 There are dedicated refiners for PM-4 & 6 having 200 kw & 350 kw motors because of different quality requirements on both M/cs. While in BCP run on PM-6 degree SR requirement is less hence small refiner is being used for PM-6 & resulted in power saving.  Power saving = 31.23 kwh Power saving = 266080 kwh p.a Availability 80% = 212864 kwh p.a Cost of own generation= Rs. 1.20 / kwh Saving in Rs. = 2.55 Lacs p.a. Investment: Nil .

  22. Best Energy Saving Practices At Ballarpur Project/ Measures No. 8 Reduction in power consumption by reducing Fresh water consumption Water Consumption in Yr 2002-03 = 20071252 Water Consumption in Yr 2003-04 = 18870131 Saving of water = 1201121 M3 = 12.01 Lac M3 p.a. Power saved = 886231 kwh p.a. Cost of own generation = Rs. 1.20 / kwh Saving in Rs. = 886231 x 1.20 = Rs. 10.6 lacs Saving in Power = Rs. 10.60 Lac p.a. (for Pumping from River) Investment: Rs. 0.25 Lac (No Major Investment)

  23. Best Energy Saving Practices At Ballarpur Project/ Measures No. 9 Reduction in Steam distribution Losses. Improving Insulations & prompt attention on leakages resulted in reducing the steam distribution losses by 0.34% Saving in Steam = 4554 MT Steam Coal / Ton of H P Steam = 209 kgs = 4554 x 0.209 Saving in Coal = 973 MT Coal Cost of Coal Rs./ MT = 1355/- Saving in Rs = 973 x 1355 = 13.18 Lacs p.a. Investment: Rs. 8.00 Lacs on insulation

  24. Best Energy Saving Practices At Ballarpur Project/ Measures No. 10 Replacement of 90 nos. conventional tube light fittings with energy saving electronic fittings Saving in Power = 13 watt per tube =13 x 90 x 24 350 /1000 kwh p.a. = 10249 kwh Cost of own generation = Rs. 1.20 per kwh Saving in Rs. = 10249 x 1.20 = 0.12 Lac p.a. Investment: Rs. 0.31 Lacs

  25. Best Energy Saving Practices At Ballarpur Project/ Measures No. 11 Optimization of Power factor of MSEB supply to maintain power factor to 0.97 by adding 300 KVAR capacitors. Resulted savings of Rs 2.4 lacs in Power Bill Investment Rs. 1.5 Lacs .

  26. Best Energy Saving Practices At Ballarpur Project/ Measures No. 12 Repositioning of Vacuum Pump Silencers. In PM - 6 & 5 pumps were having silencers in discharge line at the height of 3 Meters due to which water was being pumped & discharged at height resulting higher power consumption. These silencers repositioned at ground level with pump & resulted in total power saving of 29.25 KWh Saving in Power = 249210 kwh p.a. Cost of own generation = Rs. 1.20 / kwh Saving in Rs . = 249210 x 1.20/ 100000 Saving in Rs. = 2.99 Lac p.a.  Investment: Rs. 0.50 lacs 

  27. Best Energy Saving Practices At Ballarpur Project/ Measures No. 13 Optimization of Operations by running single DDR at PM-3 during Higher GSM Production 70 & above GSM = 20060 MT R.Hrs of DDR for above Prodn = 2809 Hrs Power consumption of DDR /Hr = 242 kw Power saved = 2809 x 242 = 679778 kwh Cost of own generation = Rs. 1.20 / kwh Saving in Rs. = 679778 x 1.2 Saving in Rs. = 8.16 lacs p.a

  28. Best Energy Saving Practices At Ballarpur Project/ Measures No. 14 Reduce the number of steps Utilization of direct heat of blow vapors in Blow heat Recovery Advantage: Resulted in reduction of steam consumption from 0.850 to 0.788 MT / ton of pulp. Saving in Coal = 1347 MT p.a. Cost of coal = Rs. 1355 per MT Saving in Rs. = Rs. 18.25 Lac p.a. Investment Rs. 1.8 Lacs for pipe line & heat exchanger modification. Implementation : Successfully implemented with a saving in coal to the tune of 1347 MT p.a.

  29. Best Energy Saving Practices At Ballarpur Project/ Measures No. 15 Reduce Wastes/Losses Utilization of Flash Steam of PM-6 by providing in-house Condenser We have installed one old condenser near PM-6, by using its flash steam, hot water is generated & sent to pulp mill for use. Saving in Coal = 672 MT p.a. Cost of coal = Rs. 1355 per MT Saving in Rs. = Rs. 9.10 Lac p.a. Investment Rs. 0.5 Lacs for pipe line etc. Implementation : Successfully implemented with a saving in coal to the tune of 672 MT p.a.

  30. Best Energy Saving Practices At Ballarpur Project/ Measures No. 16 Use Judiciously Utilization of PP-3 extraction steam in its gland. 3Kg LP extraction steam is being used in place of HP steam thus saving of heat energy difference of both steams. Saving in Coal = 11.36 MT p.a. Cost of coal = Rs. 1355 per MT Saving in Rs. = Rs. 0.15 Lac p.a. Investment : Nil Implementation : Implemented successfully during PP-3 shut.

  31. Best Energy Saving Practices At Ballarpur Project/ Measures No. 17 Use Judiciously Replacing partially RB-1 Air Preheater MP steam with LP Steam (0.632 T/hr) to enhance Power Generation from turbine by 202001 units per annum. RB-1 primary air Preheater was having three heating coils with MP steam heating. It has been modified by adding one additional heating coil with LP steam & converting one coil from MP to LP steam that has saved MP steam. Additional power Gen = 202001 units/annum Saving (@Rs.1,25) = Rs. 2.52 Lacs Investment Rs. 1.25 Lacs Implementation : Successfully implemented during Recovery boiler shut

  32. Best Energy Saving Practices At Ballarpur Project/ Measures No. 18 Correct Sizing is the key Providing higher size Steam Traps in L & T Heaters to reduce steam loss. After providing the higher size traps by passing of traps is stopped bypassing resulting in steam saving. Saving in Coal = 73.85 MT p.a. Cost of coal = Rs. 1355 per MT Saving in Rs. = Rs. 1.00 Lac p.a. Investment Rs. 0.65 Lacs Steam traps & Valves etc. Implementation : Successfully implemented with a saving in coal to the tune of 73.85 MT p.a.

  33. Best Energy Saving Practices At Ballarpur Project/ Measures No. 19 Cut the Wastes Installation of thermo pump on PM-6 to lift pre dryer group condensate. Condensate from PM-6 pre-dryer group was being drained. One Thermo pump Installed to lift & sent it to its condensate Tank. Saving in Condensate = 4200 MT/annum(50%Capturability) Cost of condensate = Rs. 30 per MT Saving in Rs. = Rs. 1.26 Lac p.a. Investment Rs. 1.60 Lacs for Thermo pump, pipe line & valves Implementation : Successfully implemented with a saving of Rs.1.26 Lacs p.a.

  34. Best Energy Saving Practices At Ballarpur Project/ Measures No. 20 Use the location advantages fully Modification of boiler feed water pump system to save power. We have increased the head of smaller feed pump (200HP, 55cum/hr & 555mtr head) by using a booster pump of 7.5 kw which enabled to run smaller feed pump with increased head in place of big pump of 350 HP at old feed pump station. There was a reduction of 80 KW in the running load. Saving in Power = 672000 KWH p.a. Cost of own generation = Rs. 1.25 per kWH Saving in Rs. = Rs. 8.40 Lac p.a. Investment Rs. 1.00 Lacs for pump, pipe line & valves. Implementation : Successfully implemented with a saving in Power 6.72 lac kWH p.a.

  35. Best Energy Saving Practices At Ballarpur Project/ Measures No. 21 Harness technical advantages fully Installation of Variable frequency drive on Decker to save power. Decker dyno drive has been replaced with Variable frequency drive resulted in Power saving. Saving in Power = 13 kW = 13 x 24 x 350 kWH p.a. Cost of own generation = Rs. 1.25 per kWH Saving in Rs. = 1.365 Lac p.a. Investment : Rs.1.65 Lacs Implementation: Successfully implemented

  36. Best Energy Saving Practices At Ballarpur Project/ Measures No. 22 Make use of nearby spare capacities. Installation of Trim blower for Jagenberg Rewinder to save power. We have installed one Trim Blower & diverted its trims in a common Pulper, which has resulted in shutting down the dedicated Pulper & Achieved Power saving of 46 Kw. Saving in Power = 391920 kWH p.a. Cost of own Generation = Rs. 1.25 per kWH Saving in Rs. =4.89 Lac p.a. Investment : Rs. 1.65 Lacs for Trim Blower & Pipe. Implementation : Implemented successfully

  37. Best Energy Saving Practices At Ballarpur Project/ Measures No. 23 Use Power Saving Methods Replacement of tube fittings with power saver electronic chokes. Approx 70 tube fittings replaced with power saver electronic chokes, which saved 13 watt per tube ie 7972 kWH per annum Saving in Power = 7972 kWH p.a. Cost of own Generation = Rs. 1.25 per kWH Saving in Rs. = 0.10 Lac p.a. Investment : Rs. 0.25 Lacs Implementation : This is successfully implemented.

  38. Best Energy Saving Practices At Ballarpur Project/ Measures No. 24 Use Power Saving Methods Replacement of inefficient FD fan of Recovery Boiler No.1 We have replaced Recovery Boiler No.1 FD Fan with Efficient Fan, which has resulted in power saving of 46 kW. Saving in Power = 391920 kWH p.a., Cost of own Generation = Rs. 1.25 per kWH Saving in Rs. =4.89 Lacs p.a. Investment : Rs. 5.00 Lacs Implementation : This is successfully being practiced .

  39. Best Energy Saving Practices At Ballarpur Project/ Measures No. 25 Reduce the excess weights Replacement of Cooling tower Aluminum fan No.3 with FRP power saver fan of PP-1 Third Compartment Power Plant No.1 Cooling tower Aluminum Fan changing into SS Hub & FRP (Hollow) blade construction, there is a reduction in power consumption to the tune of 8 kW. Saving in Power = 8 kW x 24 Hrs x 360 Days /100000 = 0.691 Lac kWH p.a. Cost of own generation = Rs. 1.25 per kWH Saving in Rs. = 0.864 lac p.a. Investment Rs. 1.00 Lacs Implementation : Successfully implemented.

  40. Best Energy Saving Practices At Ballarpur Project/ Measures No. 26 Integrate Energy and Quality Requirements Grinding of PM-4 Dryers, addition of one Dryer for increasing the speed & reducing the specific steam consumption PM-4 Dryer Cylinders were grinded on site by M/s Pikoteknik Finland. Saving in Steam = 0.348 MT/HR LP steam = 0.333 MT /HR MP steam = 0.333 x 24 x 360 Days = 2877 MT Steam Equivalent Coal = 2877 x 0.211 = 607 MT Cost of Coal = Rs 1355 Saving in Rs. = 8.22 Lac p.a. Investment Rs. 100 Lacs for Grinding & related jobs. Implementation : Successfully implemented with a saving of Coal by 607 MT.

  41. PM-4 Dryer Grinding Grooves Before Grinding After Grinding • Improved Reel Building • Improved Paper sheet flatness • Paper Moisture increased from 3.5 to 5 % • Reduction in steam consumption 0.333 T/Hr

  42. PM-3 Dryer Grinding Grooves Before Grinding After Grinding • Improved Reel Building • Improved Paper Sheet flatness • Paper Moisture increased from 3.5 to 5 % • Reduction in Steam consumption from 0.2 to 0.3 T/Hr

  43. Energy Conservation Completed TQM Projects • Reduction in power Consumption by reducing Frequency from 49.8 to 49.6 Hz • Reduction in Raw water consumption across the mills • IPO Coal Consumption • To identify potential area of Steam & power reduction in mills • IPO Cooking to reduce Re-blows • IPO Steam distribution system to reduce loses • Replacement of Inefficient Cl2 Compressor

  44. IPO Water supply to Evaporators surface condenser by shutting one pump IPO Vacuum pumps in paper M/C area to reduce power consumption IPO Power Generation to reduce steam for power Study of Pumps Efficiency consuming power >100 Kw TQM Projects Under Progress

  45. Unit: Ballarpur has Won First Prize In Industrial Sector of Maharashtra For Excellence in Energy Conservation & Management 2003

  46. We are Committedto Conserve Energyby Motivating Our Peoplefor Optimal Use of TechnologyandNatural Resourcesat an Affordable Cost

  47. Thank You

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