08.11 - ippta · owns and operates two paper mills seshasayee paper & boards limited –unit...
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V Nagarajan
Sr. Exe (Mech)
S Vigneshwar
JM (NDT)
V Madhusudan
Officer (NDT)
08.11.19
Owns and operates
❖ Two Paper Mills
Seshasayee Paper & Boards Limited – Unit Erode
Seshasayee Paper & Boards Limited – Unit Tirunelveli
❖ Sugar Mill
Ponni Sugars Limited
❖ High Energy Batteries Limited
A Battery Manufacturing Unit for Under Water
Propulsion, Aero-Space & Automotive Applications
❖ SPB Projects and Consultancy Limited
An Engineering/consulting company for Paper, Sugar and Power
❖ ESVIN advanced technologies Limited
A Technology Development Initiative Company
▪ Erode
▪ Tirunelveli
▪ Delhi
▪ Kolkata
▪ Mumbai
▪ Hyderabad
▪ Bengaluru
▪ Ernakulam
All our products are 100% Recyclable
Practicing TPM
Gold rated company for Green Practices
Product Portfolio – Writing, Printing, Posters & Speciality Boards
Cap
acit
y, t
/ an
nu
m
1960 2018
20000
165000
0
50000
100000
150000
200000
Always we can not afford to New Development Technology completely at
a time
Instead they apt for continual improvements with Small Upgradation in
plant and machineries.
Cap
acit
y, t
/ an
nu
m
20000
165000
Incremental Growth
with some
investments
2010- 20152000-2010 2018
Continuous
Improvement
Process
Innovation,
Deliberate
improvement,
Strategy Global
Manufacturing
Systems /
Industry 4.0 /
People Development
Leadership Development
2020
Sustainable Growth
With Social & Environmental
responsibilities
Tools: R-Gap, Deliberate Improvement, Bench Marking , TQM , TPM, ME
Major state of the art installations
& take over of sick units
Globally competitive
Op
era
tio
na
l E
ffic
ien
cy
Raw material up-gradation
Resource conservation
Product quality
Process improvement
Energy conservation
Environmental compliance
Research & Development for adoption
of technologies
Grab feed instead of manual feed to chippers - Manpower reduction
Drum chipper to cut large diameter logs
Chips screening - Kone screen instead of Oscillating screen to improve
production and chips quality
Grab mechanism for Wood Feeding Kone Screen for Improving Chips Quality
Chips production capacity
increased from 1100T/day to
1450T/day
Screen capacity increased
from 15T/Hr to 45T/Hr
With the screen enhancement specific energy consumption reduced from 6.6 KWh / T of chips to
5.9 KWh/T of chips
Chips packing in digesters is improved by having
Air evacuation system (for evacuating vapours in digesters)
Steam packing system (For charging of chips evenly inside
digester)
Rapid displacement of heat by way of tank form (Accumulators)
Effective way of heat recovery
This is highly energy conserving method of cooking when compared
with continuous digesters
12
Digester50%
DP - Return
50%
B C1 C2
Pre
-
Heate
r
Disp.
Tank
85°C
105°
Drum filters with vacuum system is replaced with Natural vacuum drum filters and
later with Twin roll press (For reduction of soda loss & less chemical consumption)
Better screening system (from bump rotor to step rotor)
Shell and Tube heat exchanger for black liquor / white liquor application replaced
with spiral heat exchanger to avoid scaling effect
Drum Filter Twin Roll Press
Trigger for this project
White liquor temperature could not be maintained in RDH station with the
conventional shell and tube heat exchanger.
This had necessitated to look into alternate advanced heat exchanger with state
of the art technology.
Why it is innovative
Spiral Heat Exchanger (SHE) with single flow channel and 100% pure counter
current flow heat exchange concept, produces flow path with high shear rate and
turbulence resulting in high heat transfer co-efficient and low fouling tendency.
Advantages of SHE
The continuous curving flow channel produced,
results in intense scrubbing effect that prevents
fouling of deposits formation.
The resultant overall heat exchange can be anywhere
from 30 to 50% higher than in conventional shell and
tube heat exchanger.
Eliminates leakages – Intra, external & bypassing –
Unlike S & T heat exchanger.
Compact unit –low footprint.
Parameter Present Earlier
Heat Exchanger Spiral Heat Exchanger Shell & Tube
White liquor outlet temperature 100 - 120 ⁰C 85 – 100 ⁰C
WBL supply temperature to
Chemical recovery Complex82 ⁰C 90 ⁰C
Savings calculation
Steam saving 25 TPD
Annual steam saving 9215 Tonnes
Cost saving 45.62 Lakhs
Annual GHG Emission reduction 2646 tCO2e
Replication Potential - Can be replicated by all industries.
Recovery Boiler producing 65 KSC pressure and 460 ºC SH steam production satisfies 50% energy
need of the Mill
S. No. Cause Actions taken Results
A Low vacuum in
surface condenser
Surface condenser water box leakage
arrested
Evaporation feed Rate
increased from 185 m3/hr
to 190 m3/hr
Post condenser changed over from PHE
to S&T condenser
Evaporation feed rate
increase from 190 m3/hr to
200 m3/hr
Orifice size for all NCG were modified Evaporation feed rate
increase to 203 m3/hr
Foul condensate vapor recirculation
improved by introducing POT.
Evaporation feed rate
increase to 210 m3/hr
BCooling water flow
problemFan less mist cooling introduced.
For sustainability and
spare O &M provided.
720730
768 775
806
640
680
720
760
800
840
BeforeReengineering
Surfacecondenser
bottom passpartition plate
leakage arresting
Post condenserchangeover from
PHE to SHE
Orifice sizechangeover
Foul condensatepot vapour
recirculation
1 2 3 4 5
HBL generated per day in TDS/D
PROS - Maintenance free - energy efficient system
Due to high TDS & TSS cooling tower water quality cooling tower spray nozzles
choked frequently resulting in 20% reduction in capacity of cooling tower leads to
poor vacuum and hindering pulp production .
So the alternate technology for replacing current cooling tower system to handle high
TDS water with less blow down the mist cooling technology was chosen.
The advantages of mist cooling includes, Fan less cooling resulting in power saving
and Approach (Water outlet temp – Wet bulb temperature) of 3 deg C achieved by the
project.
Operation friendly, Choking of water nozzle can be cleared while operating itself, can
take high COC and TDS cooling water.
Problem
• Settling rate is very high in dissolver tank and need recovery boiler stoppage
once in 3 months for cleaning.
Root cause
• Agitation is poor
Solution:
• Propose to increase the impeller diameter from 600 mm to 860 mm to
have a demo run with liquid with the beside spare tank for the sustained
run ability covering all aspects.
• On confirmation dissolver agitator was modified accordingly.
Benefits:
• Agitation improved (Verified after three months of running)
• Huge saving in investment cost
• Uniform concentration of green liquor
Before
shut
(GPL)
Top
sample
Bottom
sample
102.3 125.2
100.4 122.1
105.4 133.3
115.9 108.5
After
shut
(GPL)
105.4 102.3
111.6 114.1
116.6 120.9
115.9 119.7
The gpl variation of 15 to 30 has now reduced to 5 to 7
gpl.
Benchmarking
Gap Analysis
Action Plan
National &
Global best
Green Factory Initiatives
Practising 3R
Enhancing Energy Efficiency
Reducing GHG emissions
Continuous Improvement
Where We
Are
Skills Needed to
Get Where We’re goingWhere we
Need to Be
Power Reduction
11.14 Lakh kWh
Steam Reduction
24938 Tons
Coal Reduction
875 Tons
GHG reduction 1211.7 tCO2e
Furnace Oil Reduction
338 KL
GHG reduction 1043.9 tCO2e
Total
Savings
Rs. 47.45
Million
Total GHG
Reduction
2255.6
tCO2e
INNOVATIVE PROJECTS
Changes call for innovation, and innovation leads to progress
Trigger for the Project
To assess the organic load for effective treatment, the environmental cell
analyzed the various parameters to minimize the load to ETP at source.
Based on the study it is found that the pith filtrate from Bagasse pulp mill and
foul condensate from SRP tops the list.
Stream m3 / day PPM TPD
Foul Condensate 360 16000 5.4
Bagasse Filtrate 340 5620 2.2
Total 700 - 7.6
23%
9%68%
Evaporator Vacuum Pump sealing waterFoul Condensate Rest of the Mill Effluents
% of COD Contribution Mill Wide
Foul Condensate A Source of Energy
Foul Condensate generated from Evaporators contain reduced Sulphur gas,
Methanol, Turpentine etc
Foul Condensate Generation 8000 Kg / Hour
Methanol 7.5 Kg / Tonne of Pulp
Turpentine 0.50 Kg / Tonne of Pulp
TRS 1.20 Kg / Tonne of Pulp
Negative impact to the Environment is Odour
Untreated Foul Condensate is let out to the sewer creating huge impact to the
Environment by means of high BOD
Uniqueness – Treatment
in Anaerobic Lagoon
Scheme Details
An anaerobic lagoon was installed early in 1984 to treat the High BOD effluent
from Bagasse plant.
The biogas generated was let to the atmosphere without any collection device.
In 2013, a suitable supplier was identified to make a balloon cover above the
anaerobic lagoon to collect the bio gas and was pumped by a blower to the
Lime Kiln to a tune of 2000 Nm3/day.
Kiln Fuel reduction analysis – Day wise Energy consumption monitoring
148
147 146
150
148
149
149
151
149
146
136 137137
138
136
138 135
133
133
133
132
2572
3120
1733
2244
2712
4061
5310
43395499
6211
42664339
5341
3927
6217
7184
0
1000
2000
3000
4000
5000
6000
7000
8000
120
125
130
135
140
145
150
155
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Oil per Ton of Lime Kg Methane Gas flow
Outcome achieved by Project Implementation
Replication Potential – Can be replicated by all Integrated Pulp & Paper Mill
Description UOM QTY
Furnace oil reduction KL / day 3 – 3.5
Savings Rs in Crores / Annum 3.6
GHG Emission avoidance tCO2e 42439
COD load to ETP reduction % 20
Elimination of odor nuisance
Reduced energy and nutrient consumption in the aeration system
230000
240000
250000
260000
270000
280000
2016-17 2017-18 2018-19
271018
251238
275327
To
ns
Black Liquor generation
The predominant form of Biomass energy available at pulp mills is
Black liquor, the lignin rich by-product of fiber extraction from wood.
Our Sun,The bright alternative
Recognizing the importance of Solar Energy, SPB is exploiting the Solar Energy in
following ways:
Renewable Energy Sources Related Projects - 2020-21
Through Mill Development Plan, we are stepping up Pulp Production, thereby increasing
BLS generation 128 TPD of dry solids
Green Power generation 48,000 units / Day
Green Steam generation 350 Tons / Day
Project Office Admin Block Solar PV
Canteen Solar Heater Petrol Bunk
Proactive Maintenance
Predictive Maintenance
Preventive Maintenance
Breakdown Maintenance
MAINTENANCE REGIMES
UNPLANNED
(BREAKDOWN)
PLANNED
MAINTENANCE
AUTONOMOUS
MAINTENANCE
SPECIALISED
MAINTENANCE
PERIODIC
CHECKUP
(PREVENTIVE
MAINTENANCE)
OPPORTUNITY
MAINTENANCE
CONDITION
BASED
MAINTENANCE
PROACTIVE
MAINTENANCE
(PERIODIC
DIAGNOSIS
RCA WITH QC
TOOLS)
-VE
RESULTS
+VE
RESULTS
Predictive maintenance technique includes,
Vibration Monitoring
Thermography inspection
UT Leak Detector
Thickness Tester
Laser Alignement
Flaw Detector
Insitu-Balancing
CLO2 Vacuum Study using UT Leak Detector:
Problem
•Vacuum is drastically varying from 120 to 250 mmhg.
•In CLO2 plant generator vaccum-120 mmhg need to be maintained for boiling of
Chlorinedioxide.
Root Cause:
•System leak need to be check.
•Any Valve Passing need to be check.
Action Plan:.
•All Vacuum lines are checked for leakages.
•All Valves connected to Generator were checked for any air infiltration to the system.
Solution:
•Observed 2” ON/OFF valve passing
and it is connected to generator as
shown in the figure.
•After changing the valve immediately
and vacuum maintained at 120 mmhg.
Advantage UT Leak Detector:
By running itself system problem will
be identifed.No Stoopage required.
By this way following defects can be
identified using UT Leak Detector:
•Steam Trap Passing.
•Air leak.
•Diagnosis of Slow speed bearings
Pickup roll with drives removed and scrapper system introduced in BSW washer 2 with all clamping
arrangements.
• Productivity improved by about
140 tons per month
• Nil Down time from the earlier 7
hrs/month
• Inventory in procuring pickup
roll bearings eliminated
• Safety and good house keeping
Lime Kiln Shell Temperature Study using Thermography:
Shell temperature Study through Thermography advancement:•In SRP Lime kiln Area shell temperature was checked periodically.•Shell temperature checked from Feed End to Discharge End.Problem:On periodic checking shell temperature was raised to 515*C at satellite cooler area.
Action Plan:
•Lime kiln stopped and checked for any brick failure.
•Found some bricks missing in the shell area.
•Then Bricks lined to the shell area.After Rectification:•Shell temperature reduced from 515*C to 362 *C
After bricks changing
Focussed on prioritisation of Safety / Quality in production and
environment, Healthiness with respect to performance
Organisation has a strong belief, more the number of Kaizens, more
employee involvements in its functional objective.
Functional managers to promote Kaizens.
To optimise the equipments in service to run in its ideal condition by
continuous monitoring
To take care of employee welfare on different grounds by CREP activities,
Housing, Schooling at affordable cost and other social activities in and
around mill premises.
The Future Is Ours to Create
Command to consensus
Control to Commitment
Compliance to Creativity