Upload
buicong
View
219
Download
1
Embed Size (px)
Citation preview
• Established in 1960 to produce 20,000 t/annum of Printing and Writing papers.
• Current capacity - 1,20,000 t/annum at Unit : Erode & 72,000 t/annum at Unit : Tirunelveli
• ISO-9001 / ISO-14001 / OHSAS / FSC certified company.
• Practising TPM & working towards GreenCo rating.
• Company has won several awards and recognitions in Energy Conservation,
Environmental Excellence and Safety. To name a few :
National Energy Conservation Award in Paper & Pulp Sector, Dec 2014 from GOI.
Energy Conservation Award from IPMA in Jan 2015.
In recognition of excellent work done on GHG reduction, SPB-Erode was chosen by
UNIDO for first Pilot Plant Study related to GHG inventory.
National Productivity Council (NPC) published Low Carbon Initiatives implemented
by SPB in their “Best Practices Manual” on GHG reduction.
PULPING PROCESS WASHING / BLEACHINGRAW MATERIALS
PAPER MACHINEEVAPORATORRECAUSTICIZER
ROTARY
LIME KILN RECOVERY BOILERFINISHING / DISPATCH
Burnt
Lime
Lime
Mud
Green
Liquor
White
Liquor
Black
LiquorCHEMICAL RECOVERY
REDUCTION IN SPECIFIC ENERGY CONSUMPTION (SEC)
0.55
0.57
0.59
0.61
0.63
0.65
0.67
0.69
2013-14 2014-15 2015-16
0.681
0.630
0.585
SEC REDUCTION - PAT
SEC - TOE / T of Prod.
47
47.5
48
48.5
49
49.5
50
2013-14 2014-15 2015-16
50
49
48
SEC - GJ / T of Product
SEC REDUCTION – TOTAL
ENERGY
8 %
7 %
2 %
2 %
SEC IN COMPARISON TO BENCHMARKS
Unique in its operation - SPB makes a very wide range of products in a wide range of
basis weights.
Global bench marking is extremely difficult. In comparison to national benchmarks, SPB
is one of the leading energy efficient units.
Data source : TERI Energy and Environment Data Diary and Yearbook (TEDDY) 2014/15
SPB sets its own norms in relation to energy efficiency and emission intensity.
Efforts on Energy conservation, Environment protection and Emission Intensity
reduction is a continuous process involving all employees including contract labour in
our organization.
This has helped SPB achieve significant reduction in SEC on a
sustained basis as seen in the previous slide.
Entity Steam (t / t of product) Power ( KWh / t of Product)
National Avg. 11-15 1500-1700
SPB-Erode 9 1547
INNOVATIVE PROJECT - 1
Description: In Spouted bed combustion the fuel is discharged through nozzles above
the bed coils where the fuel is evenly spread over the entire cross section of furnace.
Improvement over AFBC with under-firing arrangement as it eliminates frequent tube
failures due to erosion. It can also be operated without Primary Air fan.
AFTER RETROFIT – SPOUTED BED
WITH DOUBLE BED COIL DESIGN
DECK PLATEDECK PLATE / BOTTOM
WATER WALL
BEFORE RETROFIT – BUBBLING BED
WITH SINGLE BED COIL DESIGN
Conversion of Bubbling to Spouted AFBC Boiler with increased bed heating
surface area for enhanced and efficient Steam & Power generation
FUEL DISCHARGE NOZZLE FUEL DISCHARGE NOZZLE
Benefits Achieved :
Increase in Steam generation 25 tph
Increase in Power generation through 21 MW STG 6 MW
Power saving due to Primary Air Fan stoppage 2000
KWh/day
Annual GHG Emission reduction 36000 tCO2e
Increase in combustion efficiency due to decrease in LOI 0.4 %
Increase in Boiler availability -
Replication Potential : Can be replicated by all industries.
INNOVATIVE PROJECT – 1 (CONTD)
Why it is innovative :
Spouted fluidized bed combustion – Unique and first of its kind in
Pulp & Paper sector & Cogeneration plants.
AFBC boiler operating without PA fan - first of its kind.
Description: When the steam generation increased after implementing innovative
project 1, a new boiler feed pump had to be procured.
Instead an unique strategy was formulated wherein the control valve was modified to
reduce the differential pressure. As a result, the existing energy efficient feed pump
was deemed suitable for operation thereby deferring the investment for a new pump.
Why it is innovative: Unique idea of achieving significant energy saving by re-
designing the internals of the control valve.
Benefits achieved :
Replication potential: Can be replicated by all industries for their boiler feed pumps.
Station power consumption reduction 5000 KWh /day
Net power available for export 0.2 MW
Annual GHG emission reduction 2000 tCO2e
Coal fired Boiler 10 - Station Power consumption reduction by integrating
Energy Efficient Boiler feed Pump with Low Differential Pressure Control Valve
INNOVATIVE PROJECT - 2
Why it is innovative: Clean DM water improves the heat dissipation when used as
cooling medium in the generator air coolers resulting in enhanced generator efficiency.
The DM water is returned to the de-aerator at a higher temperature. Otherwise this heat
would have been lost through the cooling tower.
Use of DM water in place of Cooling Tower Water for enhanced dissipation of
heat in 21 MW Generator
INNOVATIVE PROJECT - 3
DM
WATER
OUT
G
GENERATOR AIR COOLER
MODIFIED
DM
WATER
IN
STEAM
TURBINE
GENERATOR AIR COOLER
EXISTING
STEAM
TURBINE
G
COOLING
TOWER
WATER IN
COOLING
TOWER
WATER OUT
Trigger for the Project: The energy wasted through the cooling tower and the fouling
of generator tubes triggered the scheme development.
Benefits:
Replication Potential : Can be replicated by Thermal power plants
De-aerator LP steam consumption reduction 12 tpd
Annual GHG emission reduction 1100 tCO2e
Fouling of generator air cooler tubes is avoided -
Winding temperature reduction. -
INNOVATIVE PROJECT – 3 (CONTD)
ENCON PROJECTS AND SCHEMES WITH NO INVESTMENT(2015-16)
Description
Annual
Monetary
savings
(Rs. Lakhs)
Annual
Energy
Savings
(Electrical)
KWh
Annual
Energy
Savings
(Thermal)
t of steam
Bagasse pulp mill – Resource conservation through
capacity utilization and process optimization. 39.0 4,23,188 4147
Coal fired boiler -10 - Primary air fan stopped 21.0 5,33,625 -
Steam reduction through hot water generation from
Slaker scrubber in Recausticizer. 18.0 - 3329
Wood Fiber line - Washer spray and additional Vat
dilution pumps stopped by installing single high
efficiency pump.9.0 2,44,388 -
Paper machine 5 - Tackle pattern of HT Refiners
modified to welded bar. 8.0 2,03,656 -
ENCON PROJECTS AND SCHEMES WITH NOINVESTMENT (2015-16) (CONTD)
Description
Annual
Monetary
savings
(Rs. Lakhs)
Annual
Energy
savings
(Electrical)
KWh
Annual
Energy
savings
(Thermal)
t of steam
Water treatment plant - 2 high efficiency intake
well pumps are in operation. 3rd and 4th pumps
stopped.
12.0 3,12,775 -
Drinking water supply pump stopped for 18 h/day.
Bypass line provided from colony drinking water
line.
10.0 2,60,245 -
Paper machine 5 – Separator pump stopped.
Condensate transferred using diff. pressure
through control valve.
3.0 86,838 -
Paper machine 5 - 1 Hood exhaust fan stopped
by optimizing volume and temperature of inlet air.1.7 43,500 -
PM 1-4 stock preparation - Refiner water booster
pump stopped.0.6 18,000 -
Description
Annual
Monetary
savings
(Rs. Lakhs)
Annual
Energy
savings
(Electrical)
KWh
Annual
Energy
savings
(Thermal)
t of steam
PM 1-4 stock preparation- Fresh water booster
pump stopped by implementing water
conservation schemes.0.4 11,450 -
Total savings without investment 123 21,37,665 7476
ENCON PROJECTS AND SCHEMES WITH NO INVESTMENT (2015-16) (CONTD)
ENCON PROJECTS AND SCHEMES WITH INVESTMENT(2015-16)
DescriptionInvestment
(Rs. Lakhs)
Annual
Monetary
savings
(Rs. Lakhs)
Annual
Energy
savings
(Electrical)
KWh
Annual
Energy
savings
(Thermal)
t of steam
Coal fired Boiler 10 – Modification of
Bubbling to Spouted bed with additional
Bed & Super heater heating area.1000 1171 3,36,00,000 -
Coal fired boiler 10 - Control valve with
lower differential Pressure integrated to
energy efficient boiler feed pump.2 34 8,50,000 -
Yankee machine – Dryer cylinder
refurbishing.15 6 1,70,000 2700
Coal fired boiler 10 - VFD provided for
De-superheater pump. 5 6 1,47,000 -
ENCON PROJECTS AND SCHEMES WITH INVESTMENT (2015-16) (CONTD)
DescriptionInvestment
(Rs. Lakhs)
Annual
Monetary
savings
(Rs. Lakhs)
Annual
Energy
savings
(Electrical)
KWh
Annual
Energy
savings
(Thermal)
t of steam
Class IV vent Control valve was
replaced with Class V valve for
arresting steam passing in Recovery
Boiler.
2 86 10,30,000 8233
Paper machine 5 - White water pump
speed reduction using VFD.4 11 2,86,000 -
Coal fired Boiler10 and Recovery
boiler - Heating surface of plate heat
exchangers augmented for enhanced
heat recovery
3 3 - 654
Total 1031 1317 360,083,000 11,587
ENCON PROJECTS AND SCHEMES PLANNED DURING (2016-17)
(2016-17)Project
Estimated Energy
savings (Electrical)
KWh / day
Estimated Energy
savings (Thermal)
t of steam / day
Recovery Boiler 11 - Energy efficient Boiler Feed
Pump with low DP Control valve 2000 -
Coal fired Boiler 10 - High Energy efficient Feed
Pump with low DP Control valve – Further
improvement1200 -
Paper machine (MF2) - Insulation and modification
of steam line - 5
Bagasse pulp mill - Energy Recovery schemes in
DO-EOP-D1 Stations - 12
Installation of Bark fired Heater - 70-80
Rotary Lime Kiln - Radiation heat recovery for feed
water heating
Coal fired Boiler 10 - Direct pumping of
condensate to de-aerator 240 -
ENERGY MONITORING FORMAT
MONITORING
SYSTEM
Shift-wise
Monitoring
using DCS
Totalizers
Shift In-
Charge &
HOD
Daily Monitoring
Using
Consumption
Report
Generated by
Power Plant
HOD
&
President
(Tech.)
Fortnightly
Monitoring
through
Management
Review
President
(Tech.),
Managing
Director &
Chairman
GHG INVENTORIZATION
In recognition of excellent work done on GHG reduction, SPB was chosen by UNIDO for a
Pilot Plant Study related to GHG inventory during 2015-16. It is our intension to
continuously measure our GHG emissions and implement mitigation measures.
Mitigation Measures
Modification of Coal fired Boiler to Spouted Fluidized bed combustion for enhanced HP
steam generation
Coal fired Boiler 10 - Power reduction by using energy efficient boiler feed pump
Chemical Recovery HP Cogen – Increased Green energy Generation
Limestone & Coal/Furnace oil reduction in Lime Kiln
Energy Conservation schemes
2.515
2.318
2.096
1.8
2
2.2
2.4
2.6
2013-14 2014-15 2015-16
SCOPE 1 + 2 EMISSION INTENSITY
t CO2e / t of
product
0.228
0.22
0.206
0.19
0.2
0.21
0.22
0.23
2013-14 2014-15 2015-16
SCOPE 3 EMISSION INTENSITY
tCO2e / t of
prod.
ENVIRONMENT PROJECTS
Backwater recycling in Paper machines 1,2 & 4
to replace fresh water.
Reuse of Ultra Filtration & Reverse Osmosis
rejects along with process water.
Reuse of treated cooling water blow-down &
filter backwash.
Total Water saving : 5650 m3/day.
In addition reduction in energy and effluent
discharge was achieved.
Alkali Scrubber for mitigation of
NCG’s arising from the foul
condensate in the Evaporator.
Concentrated and toxic
compounds like reduced sulfur,
turpentine etc. scrubbed for
odour abatement and
environment protection.
Odour AbatementWater Conservation Schemes
At SPB, sustained efforts are undertaken for environmental impact reduction by
identifying the root cause and taking corrective action at source of non-conformity.
UTILIZATION OF RENEWABLE ENERGY
SOURCE
ENERGY GENERATED
THROUGH RENEWABLE
ENERGY
(000 GJ)
TOTAL ENERGY
CONSUMPTION
(000 GJ)
%
SUBSTITUTION
Chemical Recovery HP Co-
generation unit with Black
Liquor solids firing
3467 6788 51
Internally generated RE
SSI = ------------------------------------ * 100
Total Energy consumption
SSI – Self Sufficiency Index
48
50
51
47
48
49
50
51
52
2013-14 2014-15 2015-16
SSI (%)
UTILIZATION OF WASTE
Waste Material Current Use
Lime Mud Re-burnt in Lime Kiln to generate Lime for Caustisizing process.
Slaker Grits Used for cement manufacturing.
Lime Sludge Used for cement manufacturing.
ETP Filter cake Used by local board manufacturers for manufacturing Packaging
boards.
Liquid Effluent
Discharge
Treated Effluent meeting CPCB discharge norms is used for
irrigating Sugarcane plantations in the immediate vicinity.
Chipper dust and
Dry pith
Used as boiler fuel at SPB – Tirunelvelli unit & Ponni Sugars Ltd.
Bagasse pulp mill
high BOD effluent
and canteen waste
Bio-methanation of waste and biogas generated used for cooking
at guest house and staff hostel.
EMPLOYEE INVOLVEMENT AND TEAMWORKClass Room Training
1065860 855
0
500
1000
2013-14 2014-15 2015-16
Employee Kaizens Implemented
At SPB, we steadfastly recognize the value of team work in all our
Energy conservation activities.
Efforts on energy measurement and reduction is a continuous
activity at SPB.
• All Energy consumption points - Measured in each dept.
• Daily performance evaluation - Based on allocated norms.
• Daily Energy consumption reports - Compiled and forwarded
to each dept.
• Variance analysis and implementing corrective actions if
necessary by Head of the department.
• Extensive “On the job” & “Class Room” training for employee
capacity building
• Kaizens are given significant importance & recognized through
awards.
Monthly review meetings
On the Job Training
ENCON IMPLEMENTATION METHODOLOGYENCON Implementation
Scheme
generation
All
- Employees
involved
Initial
Assessment- HOD’s
Feasibility
Analysis
Energy
- Management
Cell
ImplementationProject &
- Technical
depts.
Awards &
Recognition
Senior
- Management
to employees
ISO - PREVENTIVE AND CORRECTIVE ACTIONS QMS (9001), EMS (14001) & OHSAS (18001) – ISO INTERNAL AUDIT FINDINGS
Dept/Section : Boiler & SRP (M) Auditee Name : Mr. T.R. Murthy, GM (Blr) & Mr. C.S. Radhakrishnan, AM (SRP-Mech)
Date : 20.05.16 & 21.05.16 Auditee Name : Mr. V. Parthiban, AM (Syst) – Boiler & Mr. M. Mohankumar, JM (Stores) – SRP (M)
Sl.
No.
Audit Findings (Standard, Clause No,
Requirement, Failure and Evidence)
Immediate
Correction
Root Cause of
Non-Conformity
Corrective Action to
Eliminate Root cause
of Non - Conformity
Status / Target
Date
Verification
of
corrective
action
BOILER
1 Standard : ISO 14001:2004
Clause No. : 4.4.6
Requirement : Operational control (No Leak)
Failure : Leak exist.
Evidence :
1. Steam Leak 400/150 PRDS steam
valve leak
2. Pipe line leak near C1 condense
tank
1.150 psi steam
line shut is
required to
arrest the steam
leak
2.Corroded line
will be renewed
1. Due to dead
end of the
line
2. Pipe line got
corroded
1. Isolation of 400/150
PRDS to arrest the
frequent stream
leaks, comes under
GreenCo approved
project. Material
procured. Awaiting
for 150 psi shut
2. Corroded line was
replaced
1.Completed
2.Completed
Verified &
found ok
SRP (Mech)
2 Standard : ISO 14001:2004
Clause No. : 4.4.6
Requirement : No Leakages
Failure : Condensate line Leak
Evidence : Primary Fan –SCAPH
condensate line valve gland leak
at ENMAS Boiler
Steam valve
gland was
tightened
Due to wornout
of valve gland
packing
Gland packing will be
changed. Requires
stoppage
Completed Verified &
found ok
3 Standard : ISO 9001:2008
Clause No. : 5.4.2
Requirement : Oil consumption to be maintained
within 20% per month
Failure : Oil consumption gone up 21%
during March-16
Evidence : PD Sheet
Oil consumption
is reduced during
month of Apr’16
1% exceed due
to limekiln 2B
roller temp. high.
Hence 60 tts oil
was changed
Kiln expert called for
alignment of kiln
rollers & alignment
was corrected
Completed Verified &
found ok
REPLICATION ARISING OUT OF BEST PRACTICES
Awareness Creation for stakeholders
Supplier Evaluation through Audits
TPM training programs conducted by SPB
Initiative undertaken by our supplier through guidance provided by SPB
Diesel Machine Works, PerunduraiSupplier’s Meet on 02.03.16 at SPB
PARTICULARSImprovement from Previous Years
10 Marks 15 Marks 20 Marks
Water conservation 5% 8% 10%
Power/ Steam
Conservation5% 8% 10%
Waste reduction 5% 8% 10%
ISO certification Nil Initiated Certified
Projects
implemented
Project
initiated
One
projectTwo projects
Total 4 x 10 = 40 5 x 15 = 75 5 x 20 = 100
Tray Dryer Flash Dryer
Tray dryer replaced with flash dryer atArroma Industries Ltd. resulting in asteam reduction of 14.5 %
SPB had identified selective vendors to share our best practices thereby enabling them to replicate & improve their energy efficiency
Thank You