BILT Graphic Paper Products Limited Unit...

1st Work Shop

“Best Practices in Energy Efficiency in

Pulp & Paper Sector" under KEP initiative

21st Aug.15

BILT Graphic Paper Products LimitedUnit -Ballarpur

Contents

Company Profile

Measures adopted for Energy Conservation

• Commissioning of Energy Efficient Pulp Mill

• Improving Steam Economy

• Improving Condensate Recovery

• Plant Optimization:- Shutting down of 7.5 MW TG Set

• Conversion of DC to AC drives

• Installation of VFD’s

• Optimizing Water Pumps

• Other measures

Avantha Group

• Avantha Group Companies

• BGPPL/Crompton Greaves / BILT / GGCL / APIL / Solaris Chemtech

• Turnover of Avantha Group – Rs. 20000 Cr

• BILT - India’s largest Paper Manufacturer.

• Turnover - Rs. 4500 Crores/Annum

• Total Capacity - Paper: 10,80,000 TPA.

• 7 Operations in India

• 1 in Malaysia

• Ranked among Top 100 International Paper Company list (RISI)

• Expansion with modernization for Sustainability

• Pulp mill in Ballarpur & Malaysia with state of the art technology

• Environmental, Energy & CSR conscious.

BILT Graphic Paper Products LimitedUnit – Ballarpur

• Started operation in 1953 with 25 TPD Single Paper Machine

• 360 TPD Paper Production with Six Paper Machines

• 7th Machine Commissioned in the year 2009 with 520 TPD production

• Commissioned New Fiberline of 900 TPD in 2014.

• Customers – Leading Printers in the country and overseas

• Sales turnover 1200 Crore.

• Environmentally compliant sound practices & technology

• ISO 9001:2008, ISO 14001:2004 , OHSAS 18001:2007 & ISO 50001:2011 Certified ,FSC COC & CW Certified

• DCS Controlled Operations & QCS Controlled Paper Machines

• Implemented e-business

ORACLE

OPTIVISION

ENERGY EFFICIENCY STRATEGIES

COAL SAVINGS WITH

COMMISSIONING OF

ENERGY EFFICIENT PRC

Commissioning of 900 TPD Pulp Mill

A State of Art Technology 900 TPD continuous digester Pulp mill commissioned in July 14Benefits Include: Reduced Specific Power and Thermal Energy Consumption

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Steam in Pulping

0.78 T/T UB Pulp

Power Consumption

<686 kwh/T

Steam Economy

>5.2 TPT

Chemical Recovery Efficiency

>97%

Steam in Pulping

1.8 T/T UB Pulp

Power consumption

750 kwh/T

Steam Economy in Evaporator

4.1 T/T

Chemical Recovery Efficiency

94.5%

Resource Efficient

Operations

Existing Pulp Mill Operations

Proposed Pulp Mill Operations

Pulp Mill Modernization Summary

Title Without PAT in Rs. Million

With PAT in Rs. Million

Energy savings 191.0 Million

MTOE Equivalent 18831

PAT benefit 192 Million

Total benefit 383 Million

Investment 8000 Million

NEW PRC

Bleached Pulp Production in AY 14-15 :- 191821 MT

Additional steam generation from bio mass - 191821*(0.7+0.5) = 230185 MT

With specific Coal consumption of 0.208 MT of coal per ton of steam generated , total coal savings will be 47,878.48 MT.

MTOE Savings:- 47878*1000*3933/107= 18831


STEAM CONDENSATE SYSTEM

( WASTE HEAT RECOVERY )PAPER MACHINES

Old Steam & condensate system was designed for 125 TPD production while

machine production capacity was increased to 190 TPD by increasing speed.

Higher steam Consumption in the range of 3.1 T/MT of paper.

Condensate recovery was only 35-40% due to condensate evacuation

problem/leakages.

Steam & condensate leakages from corroded lines creating unsafe condition.

Higher DP required in Rotary siphons to evacuate condensate from Dryers

means higher load on drive motors.

Frequent breakdowns of rotary siphons.

DP control system was not working properly.

PM 3 Steam & Condensate issues before rebuild

Rotary siphons requires Higher DP to

evacuate condensate from Dryers Unsafe working conditions due to Steam &

Condensate Leakages

PM 3 Steam & condensate issues

Higher Steam Consumption

Vendor recommendations for PM#3

Replace Existing Rotary siphons with High Speed Stationary siphons. These Siphons operates at low Differential pressure of 0.2-0.25 bar, low blow through steam of 15 % and 1.5-2.0 mm siphon clearance only.

A Thermo compressor based system is recommended as it provides more flexibility over cascade system.

Problems like crawling dryers as in case of rotary siphons to remove condensate before machine shut down are eliminated.

Improve PV system.

Events after Rebuild in October -14

New Siphons supplied & installed on 9th Nov.14.

• Machine performance stable in 60 & 70 GSM.

• In 80 GSM , speed initially lower by 20 MPM.

To address speed limitation issue in 80 GSM

• Siphon Clearances reduced from 8 mm 5 mm in Post Dryers .

• PD Condensate valve throttled to 50% for better heat transfer.

• Spoiler bars installed in April -15 to improve heat transfer.

• New separator added for 1st group having low steam pressure.

• Now speed is full in 80 GSM .

• Mechanical breakdowns of

dryer gear boxes & caurdon

Shaft Has come down significantly.

Spoiler bars inside dryers

Benefits of new Steam & condensate system on PM 3

Installation of new Steam

& Condensate System

Reduction in Steam Consumption


Running Load KW

S.N.Drive Name

(old Drive) DATED 7TH

OCT.14

New VFD As on

07.01.2015

1 Dryer-1 30 25

2 Dryer-2 48 32

3 Dryer-3 75 54

4 Dryer-4 32 35

8 Dryer-6 74 58

Total 259 204

Reduction in Drive Loads

Increase in Condensate Recovery in %


Steam consumption came down from 3.1 T/MT to 2.80 T/MT.

Savings in Rs = 0.3 MT*50000 MT prod*1000 Rs/MT =

Rs 150 Lac/Annum.

Condensate recovery improved up to 85 % .

Saving in Coal Rs 42.0 Lac/Annum.

Power savings due to reduction in Drive loads by 55 KWH.

Saving in Rs = Rs 17.0 Lac /Annum.

Total tangible benefits due to Steam Condensate System :-

Rs. 209.0 L

Total Investment :- Rs. 170.0 L

Simple payback :- 9.8 Months

Intangible benefits :- With reduced dryer loads , no mechanical

breakdown due to caurdon shaft & gear box failure & Drive /

motor breakdown since Dec.14


Without PAT in Rs. Million


Energy savings 20.0 Million 20.0 Million


PAT benefit 11.0 Million

Total benefit 31.0 Million

Investment 17.0 Million 17.0 Million

Similar system installed on PM- 2 ,4 ,5 & 6 in last 4 years.

Total steam savings :- 4 TPH

Equivalent MTOE :- = 2000 MT

Innovative Project


SHUTTING OF TG SET – 7.5 MW

STEAM-POWER BALANCE AFTER PP#1 SHUT

ACTION PLAN TAKEN TO SHUT PP#1

Total Mill Steam /Power was met by PP#1, PP#2 and PP#4.

Total Mill Power demand is, Average 45 MW, peak 48.5MW.

Total Mill Process steam demand was 230 TPH.

PP#1 was in operation with 4.0 MW Load and delivering 28 TPH

LP steam @ 3.9 Kg/sqcm , mostly to NPM.

LP steam pressure reduced to 3.3 Kg/sqcm

4.0 MW load transferred to PP-2 & PP-4.

ACTION PLAN TAKEN TO SHUT PP#1

Loading on PP#2 is increased from 7.8 MW to 9.5 MW after balancing its

MP and LP Extractions.

LP steam from PP#2 is @45 TPH against 30.6 TPH and MP@14 TPH to

meet Process demand.

Loading on PP#4 is increased up to 255 TPH inlet steam flow to make it

more efficient and economical operation.

Power Generation from PP#4 is 35 MW on average against 32.5 MW and

39 MW peak.

Operation economics is improved due to efficient loading of PP#4 -TG

set , which has a lowest steam consumption for generation of power on

condensing mode.

Total steam savings – 10 TPH

Self load savings of 200 KW.

PP 1 SHUT DETAILS

SL.NO.

DESCRIPTION UNIT

POWER GENERATION BEFORE SHUT PP1

POWER GENERATION AFTER SHUT PP1

INCREASE/DECREASE

1PP1 MW 3.9-4.0 0.0 Minus 42PP2 MW 7.5-7.8 9.3-10.5 Plus 23PP4 MW 32.5-33.5 34.5-36.5 Plus 3.0

SL.NO.

DESCRIPTION UNIT

STEAM CONSUMPTION BEFORE SHUT PP1

STEAM CONSUMPTION AFTER SHUT PP1

1PP1 TPH 39-40 0.0

2PP2 TPH 67-70 85-883PP4 TPH 215-218 228-230

TOTAL TPH 320-330 313-318

STEAM SAVINGS FOR LOAD SHIFTING FROM PP1

TOTAL STEAM SAVINGS

PP1 9.98-10 TONS/MW

PP2 8.8-9.0 2MW(10-9)=2.0 MT 11.0 MTPP4 6.64-7.0 3.0MW(10-7)=9.0 MT

NET SAVINGS

Benefits of Shutting of PP-1

Before Shutting PP-1 After shutting PP-1

TG SET Inlet steam

Power Gen. MW

Inlet steam

Power Gen. MW

PP-1 38.4 3.82 0

PP-2 78.5 7.79 84 9.95

PP-4 217.2 32.58 240 34.53

TOTAL 334 324

STEAM SAVINGS 10 TPH

STEAM SAVINGS –10 TPH * Rs. 1000 /MT*8760*0.9= Rs.7.8 CRORE

Benefits of Shutting of PP-1



Energy savings 78 million


PAT benefit 66.9 million

Total benefit 144.0 million

Investment Nil


REPLACEMENT OF DC DRIVES WITH AC

DRIVES-PM-3

AREA :- PM-3 Drive System (wet section)

Expected Benefit :-Energy saving of around 60 KW.Easy Fault diagnostic .Online Trends of Faults/ Alarms Annual monetary savings of 60

KW*8760*0.9*Rs. 3.8= Rs. 18.0L

Status :- Commissioned on PM-3 Shut

Before ( Analog DC Drive )

After ( Digital AC Drives Panels )

Job: Replacement of Sectional DC drives of PM-3 Wet part with ABB AC drives (8nos)

(A) PM3 Wet Section Drive Load speed/gsm

468/70

Running Load KW

S.N. Drive Name(old Drive) DATED

7TH OCT.14New VFD As on

13.11.2014New VFD As on

07.01.2015

1 Dandy Roll 2 1 1

2 Suction Couch 43 23 24

3 FDR 53 38 36

4 Suction P/U 56 47 48

5 Grooved Roll 37 33 26

6 3rd Press Top 28 33 34

7 3rd Press Bottom 43 33 34

262 208 203

Benefits of Converting DC drives to AC drives



Energy savings 1.8 Million 1.8 Million

MTOE Equivalent 128

PAT benefit 1.3 Million 1.3 Million

Total benefit 3.1 Million

Investment 11.0 Million


CHILLER OPTIMIZATION

CLO2 PLANT CHILLER- Capacity 13.5 TPD

Project Background :-Chilled water drained during lower load operation of plant <9-10 TPD to maintain chilled water flow of 70 M3 against 95 M3.Lack of support from OEM for commissioning of system & FT 239.

Status :- Commissioned with steam savings of 10 TPD during partial CLO2 plant operation.Monetary Benefit:- 10 TPD*365*0.4*Rs. 1000per Tons=Rs. 15.5 L

MTOE :- 119.6 TOTAL MONETARY BENEFITS:- 15.5+ 119.6*10200= Rs. 27.7 L with 0.5 L Investment

Action Taken :-In house solution thru EnMS 50001 approachFish & Bone diagram methodology Criteria established to define projects with significant potential.Logics developed by Instrumentation team in consultation with Process team.Chilled water circulation valve taken in line

VAM -1

VAM -2

AHU VAM Steam

conde

nsate

return

From MP steam

Header 9.2 bar

Saturated

98 M3/hr

make up

water at 2.5

to 3.5 bar

F.T

40 m3/hr to

80 m3/hr to

New ClO2

plant

Chilled

water

recirculatio

n Valve

PT

To Old ClO2

Plant

Chilled water to DCS rooms

Ele. MCC rooms circulation

Chilled

water

CHILLED WATER UNIT


USAGE OF VFD’S

Installation of VFD on WBL feed pump in New Evaporator plant

Project Background :-Earlier Flow of WBL Feed Pump was being controlled through Isolation control valve at an average manual valve opening of 30-40%.

Action Taken :-In the monthly inhouse meeting to review significant aspect for energy savings , decision taken to install VFD.

Details of calculation

WBL feed pump capacity : 90 KW

Earlier running KW with DOL: 71 KW at 30-40 % Valve Open

Present Running load with VFD 21 KW at controlled speed

Reduction in KW after VFD control: 50 KW

Cost Benefit:50*24*350*Power cost @Rs.4.00/- condensing

power

Rs.16.80 L per annum

Investment: Rs. 5000 and VFD arrange In House

COAL CONSUMPTION IN MT

EXPECTED MONETARY SAVINGS IN 15-16 OVER 10-11= INR 800 MILLION

ENERGY COST REDUCTION STRATEGIES

FUEL SWITCH IN ROTARY LIME KILN

Saving / Annum in Lac : 363

Saving / Annum in Lac : 660

ROTARY LIME KILN

PG PLANT

PET COKE

ROTARY LIME KILN

Cost comparison

Input BASIC PRICE

GCV Kcal/Kg

Cost , Rs Basis 1 KL F Oil

Furnace Oil

Rs. 40000/KL

10200 30000

Producer Gas

1300 26000

Pet Coke Rs. 15000/Ton

8200-8400

18000 Pet coke price Rs 15000/MT

1 KL F Oil will be replaced by 1.2 MT Pet coke

Cost comparison

Lime cost comparison with and without P G PlantLime cost without P G Plant

Inputs / MT of LimeBallarpur

Qty. Cost Total CostFurnace Oil - Kg 190 30.00 5700.00

Lime Stone 95 4.00 380.00Total 6080.00

Lime cost with P G Plant



Lime Stone 95 4.00 380.00Coal 180 4.80 864.00

Power 11 3.00 33.00Steam 100 1.00 100.00Total 5577.00

Diff. in cost in INR 503.00Lime prod. TPD 210.0

Saving / day in Lac (210*503)/100000 1.1

Saving / Annum in Lac 363.0

Cost comparison

Lime cost comparison with and without Pet CokeLime cost without P G Plant



Lime Stone 95 4.00 380.00Total 6080.00

Lime cost with Pet Coke



Lime Stone 95 4.00 380.00

Pet Coke 108 15.00 1620.00

Power 11 3.00 33.00

Steam 100 1.00 100.00Total 5133.00

Diff. in cost in INR 947.00Lime prod. TPD 210.0

Saving / day in Lac (210*503)/100000 2.0

Saving / Annum in Lac 660.0

Have an Idea???Please share…..

Thank you

Success is never ending & Failure is never final

Coal Ton 1

GCV kcal/kg 4000

Energy kcal 4000000

MTOE 0.4

Steam Ton 1

Enthalpy of MP kcal/kg 722

Total Energy kcal 722000

MTOE 0.0722

Power kwh 1

Heat Rate of grid kcal/kwh 860


MTOE 0.000086

Power kwh 1

Heat Rate of Cogen kcal/kwh 2600


MTOE 0.00026

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