R.K.SHARMA

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R.K.SHARMA
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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
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FLOW DIAGRAM OF Paper Machine
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CENTURY PULP AND PAPER POWER ARRANGEMENTS

• 6.8 MW TG SET
• 21 MW TG SET
• 7.5 MVA CONTRACT DEMAND FROM
• UPCL

6,20,000 UNITS /DAY
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CENTURY PULP AND PAPER THERMAL ENERGY
ARRANGEMENTS 23 TPH 46 Kg/cm2 FBC C F BOILER
3 NO 25 TPH 46/Kg/ cm2
SPREADER ST CF BOILER 1 NO 50 TPH 62 Kg/ cm2
FBC CF BOILER 2 NO 40 TPH
46Kg/ cm2 CHEM REC BOILER 1
NO 50 TPH 62 Kg/ cm2 CHEM REC BOILER
1 NO 60 TPH 62 Kg/cm2 PITH / COAL FIRED
BOILER 1 NO
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THERMAL 26.36
POWER 4.02
WATER 17.64
HIGHLIGHTS
KAIZENS 9730
CHLORINE 17.46
CAPACITY UTILIZATION 101
Base 2002-03
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TOTAL ENERGY CONSUMPTION
2003-04 2004-05
2005-06 ELECTRICAL UNITS ( Lac kwh/yr )
2180.23 2131.99 2139.76 THERMAL (
Heat Value Mkcal/yr) COAL
477390 420957
384764 BLACK LIQUOR 711616.75 657786
701681 PITH
74641.25 20581.3 138399.6 TOTAL
1263648 1225752
1224844.6 Includes 4.00 lacs units used for
plant expansion
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• 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 VFDS
• ADOPT ENERGY EFFICIENT LIGHTING
• USE OF EFFICIENT EQUIPMENT
• TECHNOLOGY UPGRADATION
• ASSESSMENT AND MONITORING

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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

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ORGANISATIONAL SET UP FOR ENERGY CONSERVATION
PRESIDENT
Vice President (Elect Inst)
Loss Idn Com
TPM
EC Cell
ISO 14001/ ISO 9001/QC
Energy Centeres
Production Depart 3 Members
MR. Shop Floor Power Hou mental
Cross funct System Committee
Chem Rec Overlapping Teams
Coord. Thermal ElectInst
Committees Quality
Electrical Env Water
Circles
Water Store,Purchase Purta
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• 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

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TPM
A ZERO BASED APPROACH
ENHANCE PLANT EFFICIENCY
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ZERO BASED APPROACH
LOSS FAILURE DEFECT DOUBT ACCIDENT BREAKDOWN
0
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AUTONOMOUS MAINTENANCE( JISHU HOZEN )
MY MACHINE I MAINTAIN
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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

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TPM RE- DEFINED
TOTAL POSITIVE MIND
TOTAL POSITIVE MIND
TOTAL POSITIVE MIND
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• LOSS IDENTIFICATION COMMITTEE
• HIGHLIGHT PROCESS INEFFICIENCIES
• CHECK LOSSES OF ALKALI,FIBRE,WATER,
• CHEMICAL AND STEAM
• ARRANGE CORRECTIVE MEASURES

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• 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

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RAYON GRADE PULP SPECIFIC POWER CONSUMPTION
kwhr/ T
68
Base 976kwh/t for 2002-03
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WOOD BAGASSE PAPER SPECIFIC ENERGY CONSUMPTION
KWHr/TON
46
Base 1424 kw/h for 2002 - 03
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RAYON GRADE PULP SPECIFIC STEAM CONSUMPTION
Mkcal/T
1.466
Base 7.486 mkcal/t for 2002-03
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WOOD BAGASSE PAPER SPECIFIC POWER CONSUMPTION
Mkcal/ TON
1.985
Base 6.945 mkcal/t for 2002-03
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ANNUAL SAVING IN POWER UTILISATION WITHOUT
INVESTMENT
25
VARIABLE FREQUENCY DRIVES
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• 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
• LEDS 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

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ELECTRICAL ENERGY SAVINGS
2003-04 2004-05
2054-65 NO OF SCHEMES 41
34 111 SAVINGS / ANNUM
KWH (LACS) 78.614 39.72
84.75 Rs ( LACS) 165
83.41 177.975 INVESTMENT
138.56 86.2
85.667 COST OF ELECTRICITY Rs
2.10
Rs 426.385
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• THERMAL ENERGY CONSERVATION SCHEMES
• EFFICIENT MEANS OF HEATING
• EFFICIENT HEAT TRANSFER
• OPTIMIZATION OF BOILERS FOR COMBUSTION,
• FLUE GAS TEMPERATURE,EXCESS AIR
• INCREASED UTILISATION OF PITH
• MINIMIZE THERMAL LOSSES WASTAGES
• THRUST ON WASTE HEAT RECOVERY

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• ENERGY CONSERVATION MEASURES
• IN PROCESS
• CAPACITY MATCHING WITH THE REQUIREMENT
• PREVENT IDLE RUNNING OF EQUIPMENT
• USE OF CONTINUOUS PROCESSINSTEAD OF
• BATCH PROCESS
• REEL TURN UP SYSTEM ON PAPER M/CS
• USE OF HIGHER EFFICIENCY EQUIPMENT
• THRUST ON WASTE HEAT RECOVERY

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THERMAL ENERGY SAVING SCHEMES
2003-04
2004-05 2005-06 NO OF SCHEMES
7 12
14 SAVINGS PER ANNUM Mkcal
143608 81752.4
222937 (EQ COAL ) 35902
20438.1 55734.25 Rs LACS
976.746 436.38
1227.015 INVESTMENT
755.29 443.47
2675.72 COST OF COAL Rs 1850/TON
Rs 2644.791
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1
Replaced of 40 W tubes by 36 W. (1000 no)
2003-04
0.350
0.66
0.176
Replaced of conventional chokes with energy
efficient chokes (400 no)
2003-04
2
0.173
0.346
1.44
Installation of Neutral Compensators.
3
2003-04
0. 51
1.02
0.51
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Installation of VFD Hot water pump 3
Wash water pump UNBL 4 ST pump B1.4
stock pump
4 5 6 7
Installation of Sonic Soot blower in B4
Recovery of flash Steam from CBD tank of boiler
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Installation of wet Pith Screw press
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Removal of silica from black liquor through
clarifier and prevent chocking of evaporators
resulting in continuous running and better heat
transfer
Replacement of low efficiency motor of old mud
filter vacuum pump.
Elimination of orifice in inlet of Secondary Air
Fan of BHEL Boiler
Increased Biomass utilization by inter connection
of the gas ducting of Boiler no.4 3 to prevent
positive pressure of furnace
Increase Biomass utilization by increasing the
gap of pith screen
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Compressor unloading control changed from single
step to dual step control

• Following improvements done in compressed air
  system
•    Installation of zero loss drain valves in air
  receiver of compressor 15    Existing HOC air
  drier replaced by refrigerated air drier
• Installation of 8 no air receivers

Accurate pressure control of compressed air by
the installation of air Managers on demand side
2 no
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Improved Raw material feed, prevent jamming of
conveyor idle running of equipment result in
stoppage of RGP Chippers in one shift with out
affecting production
Reuse of VF2 back water in VF1 sprays in RGP
bleaching
Mixing of Pre hydrolysis PH Liq of RGP WITH black
Liq. And burning in Boilers. Apart from energy
savings the pollution load was also reduced
Organic solid waste collected during periodic
cleaning of PH Liq. Tank burnt in coal fired
Boilers
Conveyor no 11 carrying Pith from Depither to
Pith yard was provided with a diverter to
facilitate direct loading of Trolleys for
transportation to power house. This prevented
expenses for storage stacking of pith. It also
reduced mixing of stones in pith, absence of
stones resulted in removal of screens and higher
Biomass UTILISATION
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-
- fresh water booster pump.
5.78
2.36
2,89,000
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TOTAL ENERGY SAVINGS FOR LAST 3 YEARS
2003- 04
2004- 05 2006- 07 INVESTMENT (LACS)
893.85 529.67 2761.39 KWH
(LACS) 78.16 39.72
84.72 COAL EQ. TONS 35902
20438 55734 Rs LACS
1141.75 519.79
1404.99
Rs 3071 lacs
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• INNOVATIVE SCHEMES
• PITH CUM COAL FIRED BOILER
• SUBSTITUTION OF FURNACE OIL
• RECOVERY UTILIZATION OF WASTE
• FROM PRODUCER GAS PLANT
• UTILIZATION OF SOLID WASTE
• OPTIMIZATION OF GENERATION
• WEAK BLACK LIQUOR CLARIFIER
• DIVERTER FOR PITH CONVEYOR

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PITH CUM COAL FIRED BOILER
DEPITHING

• 1500 Kcal/Kg
• Light substance Poor efficiency
• In conventional boilers
• Requires support fuel like coal

PITH
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PITH CUM COAL FIRED BOILER

• RD BY TBW
• CONTROL COMBUSTION
• ZONE BOILER PROPOSED
• (As per patented design of
• BABCOKWILCOX USA )
• Suitable for varying quantity
• of Pith upto 80
• Investment Rs 2350 lacs
• Saving / an Rs 793.6 lacs

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ENERGY THROUGH RFO HIGH COST FUEL
PRODUCER GAS PLANT
RECALCINE
LIME
LIME SLUDGE
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ENERGY THROUGH COAL - LOW COST FUEL
PRODUCER GAS PLANT
RECALCINE
LIME
LIME SLUDGE
INVESTMENT Rs 338.0
LACS SAVINGS ANNUAL Rs 196.0 LACS
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RECOVERY UTILISATION OF WASTE FROM PRODUCER
GAS PLANT
gasification
COAL

• PRODUCER GAS
• TAR OIL
• PHENOLIC COMPOUNDS
• Soluble in water
• ORGANIC COMPOUNDS

DISPOSAL OF PHENOL WATER Painting wooden
parts of sea going vessels
DIFFICULT Tar had calorific value
CHALLENGE Seperation
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RECOVERY UTILISATION OF WASTE FROM PRODUCER
GAS PLANT
Mixture treated with soda ash which Increases the
Density of water and Tar oil floats USED IN
LIME KILN Investment 4.0 lacs Savings / an
72.0 lacs
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BAGASSE STORAGE
69
DE - WATERING PITH PRESS
CONTINUOUS DIGESTER
WASHING
BAGASSE
WET PITH 80 MOISTURE
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DE - WATERING PITH PRESS
BAGASSE
WASHING
CONTINUOUS DIGESTER
INVESTMENT Rs 348.29 LACS ANNUAL SAVINGS
Rs 134 LACS
DE WATERING PITH PRESS
50 MOISTURE PITH
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OPTIMIZATION OF GENERATION POWER GENERATION
23.5 MW
130.6
70.65
B4
BH EL
B1
B5
B6
A BL
15.0
62
46
PRDS
110.5
68.94
21 MW
6.8MW
PRDS
27.28
PRDS
COND
33.17
80.75
4.7
3.5
3.5
15.8
37.41
2.5
PLANT
10.5
10.5
PLANT
PLANT
PLANT
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OPTIMIZATION OF GENERATION POWER GENERATION
22.0 MW
133.4
50.6
B4
BH EL
B1
B5
B6
A BL
20.27
46
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PRDS
111.2
68.94
21 MW
6.8MW
PRDS
23
PRDS
COND
33.42
73.43
3.36
3.5
3.5
2.0
14.71
35.52
PLANT
10.5
10.5
PLANT
PLANT
PLANT
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OPTIMIZATION OF GENERATION

• SAVINGS
• FULL EXTRACTION AT 10.5 Kg/cm2 REDUCED
  PRDS FLOW
• HIGHER STEAM FOR COGEN
  IMPROVED EFFICIENCY
• REDUCED VENTING OF STEAM
• STOPPED ONE CFB
• DEARATOR STEAM REDUCED
• ONE BOILER FEED PUMP STOPPED
• LOAD ON COOLING TOWER REDUCED
• COAL _at_2700MT/MONTH
  Rs 583 LACS
• POWER _at_350 KWH
  Rs 56 LACS
• TOTAL
  Rs 639 LACS

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WEAK BLACK LIQUOR CLARIFIER
WPP PULP MILL
BAGASSE PULP MILL
RGP PULP MILL
SCALE FORMATION CAPACITY LOSS INEFFICIENT
EVAPORATOR
WEAK BLACK LIQUOR SOLIDS,FRACTIONAL
FIBRES EARTHY SILICEOUS MATERIAL
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WEAK BLACK LIQUOR CLARIFIER
WPP PULP MILL
WPP PULP MILL
INVESTMENT 120 LACS SAVINGS /ANNUM Rs19.29 LACS
RGP PULP MILL
EVAPORATOR
2000 m3 CLARIFIER
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DIVERTOR FOR PITH CONVEYOR
BAGASSE 1200 TONS/DAY
YARD STONES MIXED WITH PITH
65 FIBRE
35 PITH
BOILERS
PITH STORAGE
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DIVERTOR FOR PITH CONVEYOR
INVESTMENT Rs 0.5 LACS SAVINGS Rs 149.5 LACS
BAGASSE 1200 TONS/DAY
65 FIBRE
BOILERS
35 PITH
PITH STORAGE
TRACTOR TROLLY
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• ENVIRONMENTAL MANAGEMENT
• GREEN PRACTISES SYSTEMATICALLY ADOPTED
• AND INTEGRATED INTO OVERALL PRODUCTION
• PROCESS
• ENZYMATIC PRE BLEACHING
• BIO REFINING OF PULP
• COOKING AIDS IN DIGESTER
• FARM FORESTERY
• CONSERVATION OF RESOURSES
• SOLID WASTE MANAGEMENT

REQUIREMENT FOR CORPORATE RESPONSIBILITY FOR
ENVIRONMENT PROTECTION
82
WATER CONSUMPTION TREND
KL/TON
6
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WATER CONSERVATION ACHIEVED THROUGH 23 SCHEMES
IMPLEMENTED IN LAST THREE YEARS

• RECYCLING OF BLEACHING BACK WATER
• RECYLING OF SHEETING M/C BACK WATER
• RECIRCULATION OF COOLING WATER
• RECLAMATION OF PAPER M/C STOCK
• BACK WATER

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CHLORINE CONSUMPTION KG/TON
24
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• WASTE UTILIZATION
• NORMAL SAND REPLACED BY LIME STONE
• CRUSHINGS
• STONES RECEIVED WITH COAL USED FOR STONE
• PITCHING
• PH LIQUOR GENERATED IN RGP PULPING BURNED
• IN RECOVERY BOILERS TO
  SAVE COAL
• ORGANIC SOLID WASTECOLLECTED IN PH LIQ TANK
• BURNED IN BOILERS
• TOTAL SAVINGS Rs 8.94 LACS

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• PROJECTS IDENTIFIED UNDER
• CLEAN DEVELOPMENT MECHANISM
• PITH FIRED BOILER
• DEWATERING PITH PRESS
• BURNING OF PH LIQUOR IN BOILERS

APPROX CERS 11000 PA
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• ENVIRONMENTAL BENEFITS
• REDUCTION IN GHG EMISSIONS
• CONSERVATION OF NONRENEWABLE SOURCE COAL
• REDUCTION OF SOXNOX ASSOCIATED WITH
• COMBUSTION OF COAL
• GLOBAL
• REDUCTION OF GHG ( CO2,CH4 )EMISSIONS
• CONSERVATION OF NONRENEWABLE NATURAL
• RESOURSE i.e COAL

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• AWARDS RECOGNITIONS
• SELECTED AS A MODEL UNIT BY CPCB/NPC FOR
• WASTE MINIMIZATION
• AWARDED CERTIFICATE OF APPRECIATION FOR
• ADOPTING CLEANER PRODUCTION TECHNOLOGY
• UNDER UNEP
• ECO MARK FOR BAGASSE BASE PAPER BY BUREAU OF
  
• INDIAN STANDARDS
• GREENTECH INDO GERMAN AWARD FOR
• ENVIRONMENTAL EXCELLENCE 2002
• BEST ENERGY CONSERVATION AWARD BY INDIAN
• PAPER MANUFACTURERS ASSOCIATION 2003
  04
• IDENTIFIED AS ENERGY EFFICIENT UNIT FOR 2003-04
  
• BY CII
• RECEIVED ENERGY CONSERVATION AWARD FOR
• 2003-04 BY GOI
• RECEIVED ENERGY CONSERVATION
• AWARD FOR 2005-06 BY GOI

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FUTURE PLANS

Invest Savings

Rs lacs/ annum INSTALLATION OF ROTARY
COMPRESSORS 142.0 39.74 RETROFITTING OF
ROTARY LIME KILN 200
98.5 RETROFITTING OF MUD FILTER
200 58.06 RETROFITTING OF BLOW
HEAT RECOVERY 58.96 38.92
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THANKS