established in 1960 to produce 20,000 t/annum of printing...

• 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


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


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)


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


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

established in 1960 to produce 20,000 t/annum of printing...

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