Best Practices adopted by JK Paper Limited, Unit

Slide No. 1J K PAPER LIMITED…….Creating Lasting Impressions

JK PAPER LIMITED

BEST ENERGY EFFICIENCY PRACTICES AT UNIT : CPM, FORT SONGADH, GUJARAT

Presentation by: Darab Khan, GM(Project & Development)

Date : 21st Aug, 2015


JK Paper Today

An Industry benchmark with Power Packed Brands


JK PAPER LTD IS ONE OF THE LEADING COMPANIES OF JK ORGANIZATION – A PROMINENT BUSINESS HOUSE OF INDIA FOUNDED OVER 100 YEARS AGO

TyreCement

Agri Genetics

V-Belts- Oil Seals & Power Transmission Systems

Clinical Research

Hospital & Health services

USD 3.7 Billion

23 manufacturing plants

Present in 80 countries

More than 30,000 employees

Paper

Education

Dairy Products

Defence Electronics


JK’S BRANDS ARE INDUSTRY BENCHMARKS IN RESPECTIVE PRODUCT CATEGORIESPLANTS WITH STATE OF THE ART TECHNOLOGY AND MINIMAL ENVIRONMENTAL IMPACT

Panoramic view of the Unit JKPM (Orissa) -295,000 tpa)

Panoramic view of the CPM (Surat, Gujarat) – 160,000 tpa

Copier Paper (Market Leader – 26% Share)

Coated Paper ( Amongst top Two – 9% Share)

Packaging Board( Amongst top Two – 16%

Share)


STRATEGIC GEOGRAPHICAL PRESENCE

• Strategic location

– JKPM located close to raw material sources

– CPM located close to large end customers & port

• Strong distribution reach

– 4 regional offices

– 11 warehouses

– 180 distributors

– over 4,000 dealers

UNIT : CPM

Pulp (tpa) 60,500

Paper (tpa) 55,000

Pkg. Boards (tpa) 90,000

Total Production Capacity

Saleable Product : 455,000 tons per annum (tpa)Pulp : 275,500 tpa (BD)

UNIT : JKPM

Pulp (tpa) 215,000

Paper (tpa) 295,000

Combined strength of ~ 4800 employees at both the locations


VISION,MISSION & CORE VALUES


INTRODUCTION TO JK PAPER, UNIT: CPM

JK Entered in paper business in 1938.

JKPM was set up in Odisha in 1962

JK acquired CPM In 1992, and turned around it by the year 1994-95.

Paper business consolidated in 2000-01 under JK Paper Ltd.

Packaging Board Plant commissioned in 2007


JK took over the Management in July 1992

After rehabilitation full production of Pulp & Paper started in 94-95

Company’s worth became positive in June 1996 & Company came out of BIFR

purview on 17th February 1997

JK Paper Mills (Paper undertaking of JK Corp Ltd.) transferred as a going concern

to the Company from 1st April 2000

Company’s name changed to JK Paper Ltd. on 5th November 2001

Substantial expansion – Packaging Board Plant of 60,000 TPA with energy efficient

CFB and TG – 12 MW at a Capital Cost of Rs.300 Cr. Commissioned on February 17,

2007 and commercial production started from October 21, 2007.

CPM’s present Capacity of Paper & Board is 1,45,000 TPA.

POST TAKEOVER PERIOD


STRATEGIES ADOPTED TO OVERCOME THE CHALLENGES

Product development & Product up-gradation

Production capacity enhancement

Technological improvement

Organization Development interventions & effective Human Resource Management

Training & development

Innovations & continuous improvement

Implementation of TPM

Implementation of Process Based Organization (PBO).

Development of in-house strength for de-bottlenecking and Low Cost solution.

Infrastructure development

Strong team work

Focus on CSR activities


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Increase in Paper Production Capacity Increase in Board Production Capacity

Increase in Paper & Board Production Capacity

JOURNEY OF OPTIMAL PERFORMANCE .

TP

D

Years

TP

D

TP

D

Trend of production Capacity Enhancement

YearsYears Years

TP

D

Low production due to

unfavourable market

condition & change in

productmix


unfavourable market


product mix


unfavourable market


productmix


Best Practices in Energy Efficiency


UTILITY CONSUMPTION PER TONE OF PRODUCT (SALABLE PULP + PAPER +

BOARD)

Particulars Unit

Before Energy

Saving Schemes

Year (2010-11)

After Energy

Saving Schemes

Year (2014-15)

Percentage (%) of

Reduction

Power

consumptionKWH/T 937 922 1.60

Steam

consumptionT/T 7.33 6.91 5.73

Water consumption m3/T 50.80 45.17 11.08

Coal consumption T/T 1.428 1.437 -0.63*

Own Power

generation% 97.82 98.88 1.08

Grid Power

consumption% 2.18 1.12 48.63

* Coal consumption increased due to use of lignite (Law quality fuel)


SEC TARGET PAT FIRST CYCLE

0.601

0.57

0.524

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

Base Year Target Assessment

Year 2014-15

Target Achieved

2014-15

MO

ET

PAT first

cycle

Unit Value

SEC of a base

year Average of

2007-08,2008-

09,2009-10

MOET 0.601

Target of SEC

(Assessment

year 2014-15)

MOET 0.57

SEC achieved

PAT

(Assessment

year 2014-15)

MOET 0.524

Trend of SEC Target PAT First Cycle


ENERGY SAVINGS SCHEMES IMPLEMENTED

13

28

14

10

9

1.8

7 3.0

5

13.7

5

4.7

6

3.4

5

5.8

33.2

2

14.8

7

10.1

8 12.3

3

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

2011-12 2012-13 2013-14 2014-15 2015-16 (Apr-

Jun'15)

No of SchemesTotal Investment Rs. MillionSavings Rs. Million

Trend of Energy Savings Schemes Implemented Year No. of

scheme

s

Total

Investme

nt

Rs.

Million

Savings

Rs. Million

2011-12 13 1.87 5.80

2012-13 28 3.05 33.22

2013-14 14 13.75 14.87

2014-15 10 4.76 10.18

2015-16

(Apr-

Jun’15

09 3.45 12.33


ENERGY SAVING SCHEMES IMPLEMENTED IN THE YEAR

2011-12,2012-13 , 2013-14, 2014-15 & 2015-16

YEAR 2011-2012 PAPER PLANT & BOARD PLANT

Year of Implementation

Annual Electrical Savings achieved

Annual Thermal Savings Total Annual Savings

Rs. Million

Invest made.Rs. Million

Payback Months

Units Million Rs. MillionTons of Coal or Oil

Rs. Million

1 Power saving due to installation of VFD in Recovery Boiler Firing Liquor Pumps

2011-12 0.078 0.260 0.260 0.400 18.462

2 Replacement of PM-I Uhle box vacuum pump motor by energy efficient pump

2011-12 0.037 0.135 0.135 0.135 12.000

3 Power saving due to trimming of impeller of TG-IV cooling tower circulation pump.

2011-12 0.453 1.950 1.950 0.005 0.031

4 Power saving by minimising lights & lighting hrs in Power Block

2011-12 0.039 0.124 0.124 0.155 15.000

5 Power saving due to bypassing one causticizer in each of the two stages in Causticizing.

2011-12 0.104 0.451 0.451 - Immdiate

6 Power saving due to bypassing Lime sludge storage tank & pump by providing VFD in LMW-III under flow pump making closed loop with lime sludge filter vat level.

2011-12 0.125 0.540 0.540 0.250 5.556

7 Operating one Cooling Tower fan of TG-IV in Controlled temperature range.

2011-12 0.085 0.273 0.273 0.050 2.198

8 Power saving due to minimising lighting hours in Recovery Boiler

2011-12 0.025 0.106 0.106 0.055 6.226

9 Power saving due to providing level switch with auto start/stop for sand cleaner reject pit pump

2011-12 0.024 0.103 0.103 0.065 7.573

10 Power saving due to replacing old Broke Pulper No.1 "DELTA" starter by "STAR DELTA" starter

2011-12 0.170 0.730 0.730 0.360 5.918

11 Power saving due to changing the Wills Cutter Trim Blower Motor from "Delta" connection to "Star" connection.

2011-12 0.051 0.218 0.218 0.020 1.101

12 Replacement of warm water by hot water in HypoWasher Screw Conveyor.

2011-12215.00

0.826 0.826 0.031 0.450

SUB TOTAL (PAPER PLANT)1.191 4.890

215.000 0.826 5.716 1.526

13 Installation of Energy saver for lighting of Board Plant Part-II

2011-12 0.020 0.087-

- 0.087 0.342 4.504

SUB TOTAL (BOARD PLANT)0.020 0.087

-- 0.087 0.342

TOTAL (PAPER +BOARD PLANT)-2011-12 1.211 4.977 215.000

0.826 5.803 1.868


YEAR 2012-2013

PAPER PLANT yearUnits

million

Rs. In million

Tons of coal

Rs.inmillion

Total savings

Totalinvestment

paybackMonth

1 Power saving due to installation of Energy Efficient Agitators in Talcum and WGCC Service Tanks 2012-13 0.376 0.375 0.3750.053 0.141

2 Power saving by reduction of PM-II Condensate pump rpm from 1500 to 900. 2012-13 0.015 0.070 0.070- Immediate

3 Power saving due to Installation of Cooling Tower for cooling the sealing water of vacuum pump in PM-I & PM-II. 2012-13 0.226 0.750 0.7500.500 0.667

4 Power saving by operating the PM-II Condensate pump at 30 Hz instead of 50 Hz. 2012-13 0.015 0.064 0.064- Immediate

5 Power saving by minimising lighting hrs in Causticizing area 2012-13 0.018 0.082 0.0820.045 0.549

6 Power saving due to stopping Blower of instrument air dryer & providing air through tapping taken from CFB-4 FD fan duct.

2012-13 0.267 0.123 0.1230.020 0.163

7 Replacement of Normal bulbs by CFL 2012-13 0.007 0.029 0.0290.038 1.310

8 Power saving due to bypassing PM-II Machine chest Agitator (Except during run of Ledger, Parchment & MICR) 2012-13 0.169 0.778 0.778- Immediate

9 Power saving due to resetting the Agitator shut at lower level in following chests of Stock Prepn-I i) Dry Broke chest agitator ii) Wet Broke Chest Agitator iii) PDF Recovered Fibre Chest Agitator

2012-13 0.1690 0.778 0.778- Immediate

10 Power saving due to resetting the Agitator shut at lower level in following chests of Stock Prepn-II i) Stock Prepn-II ii) Refined Pulp Pump Chest iii) PDF Recovered Fibre Chest

2012-13 0.160 0.738 0.738- Immediate

11 Power saving due to putting 32 nos. of Bulbs in RLK area OFF which were remaining "ON" for 12 Hrs/Day 2012-13 0.010 0.045 0.0450.005 0.111

12 Power saving due to removing Agitator from sludge tank in ETP 2012-13 0.115 0.532 0.532- Immediate

13 Power saving due to Debottlenecking /modification of PM-II steam and condensate system 2012-13 0.877 4.042 4.0420.800 0.198

14 Power saving due to replacement of PM-I Edge cutter existing pump and motor by Energy Efficient pump and motor Grundfos make.

2012-13 0.100 0.457 0.4570.080 0.175

15 Power saving due to replacement of PM-I Edge cutter existing pump and motor by energy efficient pump and motor - Grundfos make.

2012-13 0.099 0.454 0.4540.080 0.176

16 Timer provided for auto off of AC in BU-4 2012-13 0.020 0.090 0.0900.050 0.556

17 Evaporator WBL feed change from 5th to 4th effect and stop 4th effect extraction pump. 2012-13 0.367 0.165 0.1650.100 0.606

18 Bypass Heater mixer after EOP washer 2012-13 0.181 0.825 0.8250.100 0.121

19 Reduction in LP steam extraction pressure in TG-IV from 4.2 to 3.0 KG/Cm2. 2012-13 - -70.133 0.263 0.263 - Immediate

20 Steam saving in power generation by optimising steam extraction in TG III & IV 2012-13 - -5,817.200 18.542 18.542 - Immediate

SUB TOTAL (PAPER PLANT)3.190 10.397

5,887.333 18.805 29.202 1.871


2011-12,2012-13 , 2013-14, 2014-15 & 2015-16 (contd…)


B) BOARD PLANT yearunits

Million

Rs.million

Tonsof coal

Rs.million

TotalSavings

Rs. million

TotalInvestmentRs. million

Pay backmonths

1

Power saving by reducing working hours of Halogen lamps in Wire part area by providing ON/OFF switch & educating operating crew.

2012-13 0.018 0.088 0.088 Immediate

2

Power saving due to replacement of motor of vacuum pump for Binip suction press by higher frame size motor.

2012-13 0.122 0.559 0.559 0.375 0.671

3

Power saving due to replacement of Broke Tower Agitator motor by lower rating motor.

2012-13 0.066 0.302 0.302 0.030 0.099

4

Power saving due to Middle layer stock chest (Tower No.4) Pumps & Motor replacement by low rating pump & motor

2012-13 0.170 0.783 0.783 - Immediate

5

Power saving due to installation of VFD in MG Predryer exhaust fan motor

2012-13 0.089 0.410 0.410 - Immediate

6

Power saving due to installation of soft starter for vacuum pump no. 4, all wire part of bottom layer.

2012-13 0.146 0.670 0.670 0.190 0.284

7

Power saving due to use of warm water through HP shower for cleaning of machine clothings

2012-13 0.155 0.713 0.713 0.180 0.252

8

Saving due to additional power generation on account of removing restrictions due to smaller manual valves control valve in steam line thus consming LP steam at available pressure.

2012-13 0.106 0.489 0.489 0.400 0.818

SUB TOTAL (BOARD PLANT) 0.872 4.014 - - 4.014 1.175

TOTAL (PAPER +BOARD PLANT)-2012-13 4.062 14.411 5,887.333 18.805 33.216 3.046


2011-12,2012-13 , 2013-14, 2014-15 & 2015-16 (contd…)


List of Energy Conservation Projects implemented during 2013-14

Sr No Title of Energy Saving project implemented Annual Electrical Savings

achieved

Annual thermal

SavingsTotal

annual

savingsInvest.

Made

Rs. Million

Pay back

Months

Units Kwh Rs. Million Tons of

coal

Rs. MillionRs. Million

YEAR

2013-14

1 Power saving due to bypass of street B (for bottom) layer thicked pulp chest 178,317.00 0.882 0.882 0.06 0.81

2 Power saving due to Reduction of HP swoer nozzles of 1 MM dia to 0.9 MM dia

in Pm-1 & 2

21,900.00 0.110 0.110 0.04 4.36

3 Power saving due to Replacement of talcum dissolving tank agitators (2 nos.) by

energy efficient agitators.

112,425.85 0.568 0.568 0.04 0.85

4 Power saving due to Replacement of PM-II second press vacuum pump SPDP

motor (110 KW0 with new TEFC Energy effiecient motor

18,077.00 0.092 0.092 0.12 15.65

5 Power saving due to Replacement of Helogen lamps (1000 W X 6 nos. at PM-1

& 2 operarting floor by induction lamps (70 KW X 8 nos.)

23,500.00 0.118 0.118 0.07 7.00

6 Power saving due to Replacement of SV lamps by CFL at street lights in mill

premises and at boundary wall

30,473.85 0.154 0.154 0.09 7.72

7 Power saving due to installation of capacitor at various transformer PCC end 322,000.00 1.629 1.629 0.90 6.62

8 Power saving due to New Defleker Installed 683,128.50 3.873 3.8732.23 6.91

9 Power saving due to New Disperser Installed 98,373.60 4.520 4.52010.0 26.54

10Power saving due to Replacement of ST-B pulper dilution pump by energy

efficient small capacity Motor & Pump Installed50,924.00 0.408

0.408 0.075 2.20

11Power saving due to Replacement of ST-C pulper dilution pump by energy

efficient small capacity Motor & Pump Installed64,517.00 0.306 0.306

0.075 2.90

12Power saving due to Replacement of Top layer mixing chest Pump by energy


0.075 0.012 2.06

13Power saving due to Replacement of Recovered fiber chest pump by energy


0.0910.012 1.6

14 Power saving due to Vaccum Pump Optimaization 227,760.00 2.048 2.0480.023 0.24

TOTAL 2013-14 1,864,516.80 14.874 0.00 0.00 14.874 13.75


2011-12,2012-13 , 2013-14, 2014-15 & 2015-16 (contd…)


YEAR

2014-

2015

PAPER PLANT & BOARD PLANT

Year of

Implementati

on

Annual Electrical Savings

AchievedAnnual Thermal Savings

Achieved

Total

Annual

Savings

Invest

made.

Payback

Months

Units Million Rs. Million

Tons of

Coal or

water or

steam

Rs. Million Rs. Million Rs. Million

1 Installation of Booster Pumps (2 Nos.) for increasing pressure of LP

showers

2014-15 478 2.04 2.04 1 6

2 Replacement of SV lamps by CFL at street lights in Mill premises and at

Boundary wall

2014-15 33.6 0.15 0.15 0.08 6.4

3 Replacement of Talcum dissolving tank agitators (2 nos.) by Energy

Efficiency Agitators

2014-15 126 0.56 0.56 0.5 11

4 Replacement of Halogen lamps (1000 W X 6 Nos.) at PM-I & PM-II

operating floor by Induction Lamps (70 KW X 8 Nos.)

2014-15 0.075 0.12 0.12 0.06 2

5 Replace use of Mill water for combi trimming by super clear water in PM-I. 2014-15 8400 0.15 0.15 0.12 10

6 HP shower Nozzles of 1 mm dia to be replaced by nozzles of 0.9 mm dia in

PM-I & PM-II.

2014-15 41160 0.74 0.74 0.58 9.4

7 Replacement of PM-II Second press vacuum pump SPDP motor (110 KW)

with new TEFC motor of Efficiency-1

2014-15 7.75 0.3 0.3 0.27 11

8 Installation Of Heat exchanger in PM1 steam condensate flash vapour 2014-15 4320 4.3 4.3 1.47 4

9 Replacement of fresh water by paper machine back water 2014-15 106080 1.7 1.7 0.53 3.7

10 Installation of new wedge filter for water of edge cutter nozzles in PM1 &

PM2

2014-15 0.12 0.12 0.15 15

TOTAL (PAPER +BOARD PLANT) 645.425 3.29 159960 6.89 10.18 4.76


2011-12,2012-13 , 2013-14, 2014-15 & 2015-16 (contd…)


YEAR

2015-2016 PAPER PLANT & BOARD PLANT

Year of

Implementati

on

Annual Electrical

Savings ExpectedAnnual Thermal Savings

Expected

Expected

Total Annual

Savings

Invest

made.

Payback

Months

Units Million Rs. Million

Tons of

Coal or

wateror

steam

Rs. Million Rs. Million Rs. Million

1 Increase the production of bleach plant by using osscilatory back shower

in BF1,BF2,BF3 & BF4 for proper cleaning of wire face.

2015-16 408 2.24 2.24 0.8 5

2 Recovery Boiler MDT Level control using VFD 2015-16 42.048 0.23 0.23 0.25 13

3 Recovery BBAMT tank level control using VFD 2015-16 35.04 0.16 0.16 0.21 16

4 CFB No. 3 & 4 return cooling water line replacement 2015-16 34000 0.61 0.61 0.45 8

5 Power savings by providing auto start/stop in screening pit tank pump 2015-16 28.14 0.1 0.1 0.075 9

6 To install new LP shower pump (40 m3/hr) for breast roll & head box

shower in PM 2

2015-16 83.2 0.64 0.64 0.44 9

7 To connect decker filtrate line to suction of black liquor supply pump to

run bleach plant continuously

2015-16 0.5 2.77 2.77 0.23 1

8 Replacement of CFB no.3 start up vent valve 2015-16 0.53 0.58 0.58 0.28 6

9 Saving of steam in bleach plant by using hot water in BF1 & BF2 spray

shower

2015-16 57120 5 5 0.72 2.6

TOTAL (PAPER +BOARD PLANT) 189.458 4.48 91743 8.676 12.33 3.455


2011-12,2012-13 , 2013-14, 2014-15 & 2015-16 (contd…)


ThemePower Saving by Installation of VFD

in CFB#4 Root Blowerpower block

Before After

CFB IV root blower 2 Nos (1 Working+ 1

Standby) were of air delivery capacity of 3762

M3/hr at 3400 mmwc pressure. It was running at

full load and consuming 30 KW power. But our

requirement was maximum 1800 m3/hr air at

1400 MMWC pressure.,

Trials conducted with spare available VFD and found

satisfactory operation at air delivery of 1800 m3/hr at

1400 MMWC. Vent opening has reduced from 38% to 18

% and power consumption reduced. In view of the

foregoing, we have installed new VFD in one of the two

Root Blowers .

Power savings KWh/Annum (22.05-15.5)X24X350=55020

Power cost Rs./KWh 4.61

Total savings Rs lacs/Annum 55020X4.61= 2.54

Investment Rs. Million Total Annual Savings Rs. Million Payback Period Months

0.16 0.25 7.70

ENERGY SAVING THEMES



1.86 9.87 2.26

ThemePower Factor Improvement

From 0.82 to0.88Paper Plant

Before After

Plant load had been increased from 15 MW

to 16.28 MW .Due to increase in load,

power factor dropped from 0.88 to 0.82.

Power factor has been increased from 0.82 to 0.88 by using

capacitors at different PCCs and MCCs. The savings in power

is due to the reduction in heat losses

Reduction in power loss in cable from HT side breaker (6.6 KVA) to Transformer (P)=I²R=(57.115)² X 0.57

=1.88 KWh

Reduction in power loss in cable from transformer to PCC LT side (415V) (P)=I²R=(908.4)² X 0.35

=285.048 KWh

Reduction in power loss in cable from PCC to MCC(P)= I²R=(908.4)² X 0.04

=31.78 KWh

Power savings KWh/Annum (1.88+285.05+31.78)X24X350

=2677080Power cost Rs./KWH 4.61

Total savings Rs. lacs/Annum 2677080X0.8X4.61=98.73

ENERGY SAVING THEMES (contd…)


Investment Rs. Million Total Annual Saving Rs. Million Payback Period Months

0.890 3.97 2.70

Theme

Utilization of All Coal Fired Boilers

and Liquor Fired Boiler CBD & IBD

hot water in Causticizing & pulp

mill

Pulp Mill & Soda Recovery

Before After

All boiler CBD & IBD hot water of 90 deg. C

was drained @ 120 TPD(i.e. 120 m3/day) This

CBD & IBD hot water contains some amounts of

silica, which can be used as a process hot water

in pulp mill and Recovery plant.

CBD & IBD hot water of 90 deg C @ 120 TPD utilized

in pulp mill Causticizing hot water tank in which steam

was being consumed to raise the temperature of mill

water from 30 to 90 deg. C.

Water savings m3/Annum 120x350 = 42000

Water cost Rs./m3 5.00

Steam savings T/Annum 120X60X350/540=4667

Steam cost Rs./T 806

Total savings Rs. lacs/Annum 42000X5+4667X806=39.71



Investment Rs. Million Total Annual savings Rs. Million Payback Period Months

0.06 0.21 3.42

Theme

Replacement of

Normal

Bulbs by CFL & LED

Electrical

Before After

Earlier we were using normal bulbs

at home of 100 W, 60W, & 40W,

which were consuming more power

at an average 200 W/hr per house

considering use of 8 hrs.

Normal bulbs have been replaced by less power consuming CFL

and LEDs of 9W, 11W, & 20W,Which reduced the power

consumption up to 160 W. At present the power consumption per

house is 40 W only. Daily use at an avg. 8 hrs and total no. of

houses where this replacement has done is 100. Power Saving

(200-40)=160 W.

Power savings KWh/Annum 160X8X100X350=44800

Power cost Rs./KWH 4.61

Total savings Rs.lacs/Annum 44800X4.61=2.07




NA 16.35 Immediate

Theme

Steam saving in power

generation by optimizing

steam extraction in TG 3 &TG 4

Power Block

Before AfterEarlier extraction steam was equally

distributed in both turbines and power

generated was almost equal

By optimizing the steam flow in TG 3 and TG 4 , total power

generation remains same and steam consumption reduced

to 2T/Hr

Parameter TG3(12 MW) TG4(12 MW) Parameter TG3(12 MW) TG4(12 MW)

Power 8.45 MWH 8.68MWH Power 6.63 MWH 10.45 MWH

MP 10 TPH 10 TPH MP 15 TPH 5TPH

LP 48TPH 38TPH LP 38TPH 48TPH

Condenser 13TPH 10TPH Condenser 8 TPH 13TPH

H P Steam 71TPH 58 TPH H P Steam 61TPH 66 TPH

Total Steam = 129 TPH, Power Generation = 17.12 MWH Total Steam = 127TPH, Power Generation = 17.08MWH

Saving of steam tons/Annum 2X24X350=16800

Coal consumption reduced

(Evaporation ratio= 3.8)

MT 16800/3.8= 4421

Cost of coal Rs./T 3700

Total Savings Rs. lacs/Annum 4421 X 3700=Rs.16357894



ThemeReplacement of Broke Refiner by

DeflakerBoard Plant

Before After

We were running broke refiner for broke

handling.Broke refiner was very old design and

installed along with SAPPI machine.

Deflecker was installed in place of this broke refiner

for better broke treatment which is more energy

efficient and less power consuming. Earlier power

consumption was 210 KWh ,new Deflecker running

power consumption is 110 KWh

Power savings =210-110=100 KWh


2.23 3.87 7.0

Power savings KWh/Annum 100 kwh x24 x350 =840000


Total savings Rs lacs/Annum 840000X4.61=38.73



SAVING IN DISPERSER OLD(KWh) NEW(KWh) SAVING(KWh)

PRECOAT 119 73.4 45.6

BACK COAT 105 55.1 49.9

TOP COAT 107.1 92.7 14.4

CLAY 79.1 72.3 6.8

TOTAL 410.2 293.5 116.7

ThemeReplacement of Old Disperser by

New Disperser

Board Plant

Before After

We were running disperser of very old design

and installed along with SAPPI machine. It was

having DOL starter & dual speed motor.

Advanced version of new disperser with VFD controlled

installed which is more energy efficient and less power

consuming.


10.0 4.52 26.5

Power saving KWh/Annum 116.7X24X350=980280


Total savings Rs. lacs/Annum 980280X4.61=45.2



ThemePower saving due to Vacuum

Pump optimizationBoard Plant

Before After

Vacuum pump no. 1,3,4,6,7 & 9 were running.

It was decided to stop vacuum pump no. 7

which was used for Nipco Felt.

Vacuum requirement of Nipco was fulfilled by vacuum

optimization of vacuum pump no. 9 and stopping vacuum

pump no. 7. Energy saving was done. Total vacuum

pump load previous @ 1312 A, after stoppage of vacuum

pump no. 7 total load @ 1220 A., 1312-1220= 92A


0.23 2.05 1.33

Power savings KWh/Annum (1.732X.415X92X.8)X24X350=444378.5


Total savings Rs Lacs/Annum 444378.5X4.61=20.50



ThemeEnergy savings due to removing

of control valvesPaper Plant

Before After

Power consumption was higher due to the

friction losses in the lines due to present of

control valves.

All control valves were removed & VFD provided to

control flow of liquid. Power consumption reduced by 45

KW by avoiding the friction losses due to control valves.


1.70 1.74 11.72

Power savings KWh/Annum 45X24X350= 378000


Total savings Rs Lacs/Annum 378000X4.61= 17.42



i) Dry broke chest agitatorii) Wet broke chest agitatoriii) PDF recovered fiber chest Agitator


NA 0.778 Immediate

(DETAILED TABLE IN THE NEXT SLIDE)

Power savings in dry

broke chest agitator

KWh/Annum 86798.16

Power savings in wet

broke chest agitator

KWh/Annum 35376.07

Power savings in pdf

recovered fiber chest

agitator

KWh/Annum 46691.42

Total Power Saved KWh/Annum (86798.16+35376.07+46691.42) =

168865

Power cost Rs. /KWh 4.61

Total savings Rs.lacs/Annum 168865X4.61 = 7.78

POWER SAVING DUE TO RESETTING THE AGITATOR SHUT AT LOWER STOCK

LEVEL IN FOLLOWING CHESTS OF STOCK PREP-1-


S.No Eq No PARTICULARS Units Before Scheme After schemes Savings Remarks

1 PM/c-1

Anticipatory working hours Hrs/Annum 8314 8314

2.1 821-23 Dry Broke chest Agitator2.1.1 Running Load KW 13.05 13.052.1.2 Working hours Hrs/Annum 8314 1662.8 20% RUNNING,

80% SHUT

2.1.3 Power consumption/Annum KWh/Annum 108497.7 21699.54 86798.162.1.4 Power cost Rs/KWh 4.61 4.612.1.5 Power cost saving Rs/Annum 500174.397 100034.8764 400139.5182.2 841-50 Wet Broke Chest Agitator

2.2.1 Running Load KW 8.51 8.512.2.2 Working hours Hrs/Annum 8314 4157 50% RUNNING,

50% SHUT

2.2.3 Power consumption/Annum KWh/Annum 70752.14 35376.07 35376.072.2.4 Power cost Rs/KWh 4.61 4.612.2.5 Power cost saving Rs/Annum 326167.3654 163083.6827 163083.6827

2.3 841-50 PDF Recovered Fiber chest Agitator2.3.1 Running Load KW 6.24 6.242.3.2 Working hours Hrs/Annum 8314 831.4 10% RUNNING,

90% SHUT

2.3.3 Power consumption/Annum KWh/Annum 51879.36 5187.936 46691.4242.3.4 Power cost Rs/KWh 4.61 4.612.3.5 Power cost saving Rs/Annum 239163.8496 23916.3849 215247.465

3 TOTAL POWER CONSUMPTION KWh/Annum 231129.2 62263.546 168865.6544 TOTAL POWER COST Rs/Annum 1065505.612 287034.9471 778470.665

7.78 LACS

POWER COST SAVINGS DUE TO REDUCTION IN STOCK PREPARATION CHEST

AGITATOR RUNNING TIME PM-1


THANK YOU……

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