Pulp & Paper - 378 - ITC - PSPD - Unit - Bhadrachalam - 0
Pulp & Paper - 378 - ITC - PSPD - Unit - Bhadrachalam - 0
Pulp & Paper - 378 - ITC - PSPD - Unit - Bhadrachalam - 0
Unit : Bhadrachalam
Presentation by :
M.Phani Kumar – Manager (ENCON Cell)
T.Murali Krishna – Manager (Energy & Utilities)
Liquid Pharma
Packaging Cartons Deep
Printing Freeze
Paper foods
Blister
Book
Packs
Covers
Pharmaceutical Cartons
Installed
Cogeneration
power plant of
capacity 115 MW.
Average connected
load : 95 MW.
State of Art Paper / Board machines & Rewinders High Speed Sheeters Automatic Storage & Retrieval Facility Warehouse
~ 0.5% of the Electrical & Thermal Energy saved through zero investment projects
1400 Due to
1200 BCTMP
97
Sp. Power (kWh/T)
1000
800
200
0
2013-14 2014-15 2015-16 2016-17 2017-18
3.9 %
GJ/Ton
30 2.7
25
20 39
15 27.57
25.3 23
10
5
0
National EU BAT* 2017-18
*Best Achievable
Technology
Benchmark Reference:
Centre for Science & Environment study published in 2010 for Pulp & Paper sector
Continuous focus to identify potential energy saving opportunities through audits & Studies
Objective:
Quality improvement in Super Batch Digesters
Trigger points:
More Cycle Time
Product Quality
More Chemical Consumption
Benefits:
• Overall blown pulp production increased by 5 % (4 MT per cycle)
• Shives generation eliminated
• Solids generation per ton of blown pulp reduced by 7 %
• Digester cycle time reduced by 7.1 %
• Specific power consumption of bleached pulp reduced by 25 kWh/T
• Specific steam consumption reduced by 0.05 T/ T of bleached pulp
Objective:
To meet the ash handling conveying air with one compressor
as per design and keep the other standby.
1.BAC 2. MDC
3.APH 4. ESP
Benefits
• Service air pressure variations are came down.
• Meeting air demand with single compressor.
• Power consumption reduction 125KW x 20 hrs @ Rs 3.5/kwh
• Annual Savings achieved: 32 lacs
Energy consumption is monitored by Energy Meters installed at end users & viewed
in the DCS for effective monitoring & control.
Leveraging technology & latest energy consumption monitoring
systems in place
DCS – Process & energy control for all facilities.
SCADA – Electrical energy Monitoring and Load Management
ABB Smart Client – Real time monitoring at individual desktop
xMII - Auto generated email reporting for major plant parameters
SAP – Daily Business Reporting
ExaQ – Energy optimization Software Energy Monitoring DCS Screen
Visual Mesa – Real time energy optimization software
Monthly-mill performance review reports.
Energy cell monthly report on energy consumption & conservation.
Jan-19
Aug-18
Sep-18
Feb-19
Oct-18
Jul-18
Mar-19
2010-11 Avg.
2011-12 Avg.
2012-13 Avg.
2013-14 Avg.
2015-16 Avg.
2016-17 Avg.
2017-18 Avg.
Apr-18
May-18
Nov-18
2014-15 Avg.
Dec-18
Apr-18
May-18
Mar-19
Oct-18
2010-11 Avg.
2011-12 Avg.
2012-13 Avg.
2013-14 Avg.
2014-15 Avg.
2015-16 Avg.
2016-17 Avg.
2017-18 Avg.
Aug-18
Jan-19
Jun-18
Jul-18
Sep-18
Nov-18
Feb-19
ITC PSPD (BCM) Slide # - 43
Employee Involvement - Energy Conservation Campaign
• Campaign launched at the Factory Gate on 1st February '18
• February '18 and March ‘18 declared & observed as the month of “Energy Conservation“ across all
JHs/DMTs
• Out of overall PQC category 1100 Kaizens – 347 No’s were towards “Energy Conservation” theme
• Total 42 JH teams from 15 DMTs, actively participated in this event
• Resulted savings through all forms of Energy
Projected Annual Savings
Energy Type UOM Energy Savings
in Rs.Lakhs
POWER SAVINGS kW/Hr 697.6 114.08
STEAM SAVINGS Tons/annum 622.1 1.32
CONDENSATE SAVINGS Tons/annum 432.0 6.55
COMPRESSED AIR SAVINGS Nm3/annum 931000 4.93
WATER SAVINGS (PROCESS WATER) m3/annum 22550 1.99
Total Savings 130.5
All the above ideas were conceived and implemented by Shop floor people
ITC PSPD (BCM) Slide # - 44
Employee Involvement - Energy Conservation Campaign
47.52%
52.48%
Wind Energy
Commissioned 46 MW wind power generation
facility for replacing electrical energy generated
through coal.
Biogas plant
Generating biogas from food waste & ETP
secondary sludge and used in Canteen for
cooking.
Green Boiler
A biomass fired boiler to fire plantation
biomass and coal at 70:30 ratio to utilize the
waste from plantation & Wood Bark.
Solar PV - Laxmipuram
80 kWp SPV plant installed at plantation
facility in Laxmipuram near Bhadrachalam.
Light pipes
Avoiding energy consumption for electrical lighting at daytime
Installed in TGs, Coal Bunkers, DG Plant and Work sheds
Conducted audits for Associate manufacturers & worked on targets & ways to achieve them
Introduction of excellence levels to all associates
Format developed for selection of Associates & explained to them based on their specific
energy consumption & reduction trends
Identification of best practices, sharing & rewarding the performers
Awareness creation programs conducted for Associates