knowledge exchange platform · 2016-12-21 · of best practices and new technologies. to compliment...

Knowledge Exchange PlatformKnowledge Exchange PlatformPromoting Energy Effi ciency through Best Practices in Industries covered under the

Perform Achieve & Trade (PAT) SchemeNEWSLETTER ISSUE-5, APRIL, 2016

INSIDEINSIDE Message from Secretary, Bureau of

Energy Efficiency

How to boost Heavy Industry’s Energy Efficiency

ISO 50001: Industry’s perspective- Indian Rayon, Veraval Gujarat

Best Practice Case studies• JK Paper Limited, Unit: JKPM,

Jaykaypur• Nectar Lifescience Limited• BILT Graphics Paper Products

Limited, Unit: Ballarpur

Trading of Energy Saving Certificate

The Perform-Achieve-Trade scheme in the Pulp and Paper Sector:Challenges and Achievements

Innovative Technology to Promote Energy Efficiency• Automatic Tube Cleaning System

Knowledge Exchange Platform Update

Supported by

The award winning paintings of children who participated in National Level Painting Competition -2015 organised by Bureau of Energy Effi ciency, Ministry of Power, Government of India, are presented here. Paintings of Akshita Khanna (Uttar Pradesh), Sayana T V (Kerala), Jumon Thakuria (Assam), Ritiraj (Jharkhand), Mahi Aggrawal (Uttarakhand), Ananya Sharma (Jharkhand), Fedrick Edgar Warjiri (Meghalaya), Sneha Goyal (Punjab) and Nitin Ghosh(Jharkhand) appear below in the same order.

Warm greeting to industry friends and colleagues!

At the outset, I would like to congratulate the Knowledge Exchange Platform (KEP)on completion of one year since its launch on 26th February, 2015. Many achievements have been made during this period and the platform is continuing to make steady progress towards realisation of important milestones set out in the Action plan. I would also like to acknowledge the proactive role being played by the industry and the support provided by them towards these accomplishments.The strong commitment shown by the industry for sharing of knowledge and best practices amongst their peer group has been the cornerstone of this initiative.

KEP has helped in creating a vibrant institutional framework to catalyse the transfer of best practices within and across diff erent industry sectors. The constitution of Sector Learning Groups (SLGs) for each PAT sector provided strategic guidance to these sectors. The sector level workshops being organized together with technology exhibitions and industry exchange visits, provides a platform for sharing of best practices, experiences and learnings. The series began with Aluminium Sector workshop and so far sectoral workshops have been organized for all PAT sectors. To ensure that KEP also acts a forum for sustained interaction between the BEE and Industry, a series of roundtables and blogs on important policy issues have been initiated. This has helped to get fi rst hand feedback from the industry and provided an opportunity to have continuous dialogue with the industry on various issues, challenges and policy priorities.

As we move in to the second year of KEP, it would be advantageous to add further momentum to the existing collaboration with industry by promoting technology and knowledge sharing partnerships, which can help industry meet the new targets recently announced under second cycle of PAT. The SLGs could help in formulating plans to map innovative, new and cutting edge technologies for each sector, expand the network of experts and develop strategies to promote peer to peer learning, outreach and rapid uptake of best practices and new technologies. To compliment this eff ort, the recently created database of energy effi cient technology service providers and technology suppliers among host of other resources would help industry in uptake of these best practices by building partnerships with technology suppliers and service providers.

The last one year has seen the evolution of KEP as a vibrant platform and has followed an iterative process of feedback and learning, and this newsletter has been an important medium to reach out to industry and provide a mechanism for sharing industry’s experience, reviews on new technologies, linking up with stakeholders and getting their feedback. The present issue of this newsletter covers case studies, which have been selected from pulp & paper, textile and pharmaceutical sectors. This issue also brings to you technology feature on Automatic Tube Cleaning system and technology options for boosting energy effi ciency in heavy industry along with the views of Central Pulp & Paper Research Institute on achievement of PAT targets.

As the KEP embarks on a new phase, I urge industry stakeholders to strengthen their eff orts by providing inputs and feedback to respond to their needs and provide information on new innovative technologies, practices and knowledge which could be shared through this newsletter.

Sanjay Seth

Message

Mr. Sanjay SethSecretary,Bureau of Energy Effi ciency

Newsletter Issue-5, AprIl, 20162 For circulation within the KEP network only

How to Boost Heavy Industry’s Energy Efficiency

Dr. Jigar V. Shah Executive Director, Institute for Industrial Productivity

Manufacturing is a critical and influential part of the US economy; it supports one in six private sector jobs and accounts for 65 percent of exports. And it is rapidly undergoing a renaissance due to shifting global cost structures. Now is the time for manufacturers to get the jump on their competitors through increased energy productivity.

The US government is already behind such initiatives with the Clean Power Plan now in play and promises to keep the country’s greenhouse gas emissions in check.

Industrial energy productivity is the inverse of energy intensity and is defined as production per unit of energy consumed.

The NumbersIn most countries, the industrial sector is the largest energy-consuming sector. In the US, it accounts for 31 percent of primary energy use; in China, 75 percent; and in India, 68 percent.

Energy productivity is highest in Europe and OECD Asia, where it stands around 35 percent above the world average. Energy productivity in North America is close to the world level, much lower than in Europe

and OECD Asia. The Table 1 presents data from the ABB’s Global and Sectoral Energy efficiency trends for different sectors, showing how the US fares in comparision to other countries or regions.

Improving Energy ProductivityThere are fundamental process and structural reasons for the wide differences in energy productivity across the world. For instance, the countries or regions with the largest share of electric steel (Europe, US, South Korea, Taiwan, Turkey) have the highest energy productivity.

However, the energy productivity of China’s chemical industry is low since the feedstock used is coal and not gas. Inefficient vertical shaft kilns are used in almost half of all cement production in China, lowering the sector’s energy productivity, while the US paper industry suffers due to the technical age of production facilities.

Structural factors aside, industry can make significant gains in energy productivity. The recent article, The Four Pillars of Industrial Energy Efficiency suggests these four elements should sit front and center of companies’ energy strategies: Making continual operational

improvements Ensuring effective maintenance of

equipment to reduce energy wastage Making engineered improvements, such

as new additions, modifications and

upgrades, to improve energy efficiency Implementing energy efficient new

technologies.

Of course, for these four energy productivity enablers to work, the right culture must be created within an enterprise — especially where it relates to behavior, skills, teamwork, measurement and tracking, and (especially) commitment to energy efficiency through the entire management chain.

Implementing an Energy Management SystemEnergy management systems (EnMS) provide a means for systemically analyzing, managing and reducing energy use.

They have increasingly gained attention among industry leaders who recognize their strategic potential as a means to cost-effectively save energy, reduce greenhouse gas emissions and enhance energy security.

The US has its own tailored EnMS program called Superior Energy Performance (SEP). It is an accredited, plant-level, federal program that uses the internationally-recognized ISO 50001 Energy Management Standard as a foundation.

According to the US Department of Energy, facilities certified by SEP become leaders in energy management and productivity improvement. They have met the ISO 50001 standard and have improved their energy performance (defined as energy intensity) by up to 25 percent over three years, or up to 40 percent over 10 years.

To boost broader energy productivity in the US, we will need to accelerate the adoption of SEP through state energy efficiency programs, following examples already set by some states, as documented in this Action report on the design of energy efficiency programs.

Table 1: Energy Productivity Metrics (2011)

Measure US Best performing

Electricity as % of energy consumed in industry >25% >30% (EU)

Share of combined heat and power (CHP) of electricity 28% 80% (CIS)

Steel production (t/toe)* 3 5 (turkey)

Chemical production ($2005ppp per koe)** 2.5 10 (Japan)

Cement production (t/toe)* 12 14 (Japan, Mexico, EU)

Paper production (t/toe)* 1.7 5 (South Korea)* t/toe is tonnes of production per tonnes of oil equivalent**koe is kilograms of oil equivalent

Newsletter Issue-5, AprIl, 2016 3

The Role of Best Practices in Technology and InnovationTechnology improvements and innovations in industry are remarkably slow because of the sluggish turnover of capital stock, capital-intensive investments, fluctuations in raw material availability and market demands, inadequate ROIs, and because many current processes are at their physical or chemical limits. Many of the most widely-used manufacturing processes, at a basic level, are more than one hundred years old. This list of commonly-used (energy-intensive) processes shows just how old:

Industry process Year

1800 1900

Aluminum (Hall Heroult) 1888

Ammonia (Faber) 1913

Portland cement 1900

Petroleum refinery 1856

Modern steel 1855

Sector Improvement potential (best

practices)

Best practice technologies Emerging technologies

Cement 18 percent Thermal and electrical systems efficiency Use of alternate fuels and raw materials

(AFR) Waste heat recovery (WHR)

Fluidized bed advanced kilns Low carbon cements

Iron and steel 21 percent Phase out open-hearth furnaces Limit coal-based direct reduced iron

production Greater availablility and use of scrap Systemic approaches

Blast furnace with top gas recycling Upgraded direct reduced iron process Upgraded smelting reduction process Use of hydrogen enriched reducing gas in blast furnace Electrolysis reduction

Chemicals and petrochemicals

24 percent Increased level of process integration Expansion of newer and more efficient

technologies including use of low carbon fuels and recycling

Waste heat recovery

Olefin cracking via catalytic cracking of naphtha Olefin production via methanol to Olefin Propylene peroxide via Hydrogen Peroxide Ammonia and methanol from renewable hydrogen Olefins from biomass

Pulp and paper 26 percent CHP Heat recovery & process integration Increased use of recycled pulp Continuous digester Drum pulpers

Black liquor gasification for generating electricity, bio-chemicals and bio-refinery products

Bio-products diversification, e.g. kraft market pulp mills producing dissolving pulp for the textile industry

Breakthrough concepts, e.g. production of pulp using deep eutectic solvents

Aluminum 11 percent CHP in bauxite process Heat recovery in bauxite and rolling mills Energy efficient furnaces

Alternative processes to the widely used Hall-Heroult process

Enhanced value-added products

Though the pace of innovation is slow, there is still substantial potential for improvement of energy productivity, based on the application of best practices. Here’s what IEA’s Tracking Clean Energy Progress says about the potential improvement of the different industrial sectors.

Key Elements for Creating an Industrial Energy Productivity RoadmapBest practice technologies can take us a long way towards productive and competitive industry. Depending upon the sector, the potential for improvement in energy productivity is 10 to 30 percent, with EnMS providing the required platform to identify opportunities and enable continuous improvements. There are many promising emerging technologies but many of them will not be fully realized in the next five to ten years. Areas of future focus for a long-term industry roadmap will be on productivity

and decarbonization with attention to the following areas highlighted in the UK industrial decarbonization and energy efficiency roadmaps to 2050: Carbon capture and storage, and

utilization Electrification using affordable low

carbon source Decarbonization of grid Biomass for fuel and feedstock Energy management systems Clustering of industries Circular economy

We’ve got a swathe of tools in our collective toolboxes to cut energy use and improve productivity. In the manufacturing sector, perhaps more than any other sector, the search for cost-effective ways to increase energy productivity aligns with the individual interests of private industry and the nation’s interests in economic development and a cleaner environment.

NEWSLETTER ISSUE-5, APRIL, 20164

Indian Rayon (A Unit of Aditya Birla Nuvo Ltd.) Veraval, Gujarat

– Mr. Dashrath Chouksey, Assistant Manager (IMS), Indian Rayon

About the Plant

Indian Rayon (IR), SBU of the Aditya Birla Nuvo Limited, is a leading manufacturer of viscose fi lament yarn (VFY) with a rich heritage of over 60 years. This yarn is an input to the textile industry for manufacturing fabrics used in apparel and home furnishings. With a turnover of around Rs. 699 crores/annum (FY15), Indian Rayon is a leading VFY exporter with exports to 45 countries, in addition to the lion’s share of India’s market. IR played a major role in catapulting India to the second position worldwide, as a manufacturer of VFY, with China at fi rst position.

The SBU owns completely integrated operations of capacity 19800 tons/annum, producing Pot Spun Yarn (PSY), Continuous Spun Yarn, (CSY), and the unique, patented Spool Spun Yarn, (SSY) (acquired technology in 2013 for manufacturing and marketing in India from the globally reputed ENKA, Germany). It is backwardly integrated with a 34.5 MW captive power plant and a 250 TPD caustic chlorine plant (part of the Chlor-Alkali SBU). The integrated complex is located in Veraval, Gujarat. Manufacturing and other functions are located at Veraval, and sales and marketing, in Mumbai.

Indian Rayon is unique in many ways: It is the only company to use all 3 kinds

of technology – customers can choose the VFY required at one location

It is the fi rst VFY business in India accredited with ISO 9001, ISO 14001 (Environment), ISO 50001 (Energy Management), OHSAS 18001 (Health and Safety), SA 8000, REACH Compliance and OekoTex certifi cation.

It is the largest VFY exporter from India and recipient of the SRTEPC export awards.

It is the fi rst company taking a VFY brand to the end consumer that will also benefi t the industry as a whole, in India.

Journey towards Excellence

Indian Rayon is a system oriented plant: the journey towards implementing Management Systems was started way back in 1994 by ISO 9002, and from

1996 onwards, Aditya Birla World Class manufacturing practices (WCM) were initiated. Indian Rayon is accredited with ISO 9001:2008, ISO 14001:2004, OHSAS 18001:2007 and SA 8000:2008 certifications. From 2012, Indian Rayon has been working with DuPont for implementing Behavior Based Safety and Process Safety Management. The ABG WCM framework was upgraded to a Business Excellence framework and implemented from 2014. The business is also working towards improving its energy performance and was certified as ISO 50001:2011 compliant in year 2015.

We have a strong culture of World Class Manufacturing practices involving kaizen, various campaigns, competitions and award schemes. In line with our Group’s vision of CSR, Indian Rayon has established the Jan Seva Trust (JST) in the unit, for the cause of Education, Health care, Sustainable Livelihood, Infrastructure Development and Women.

ISO 50001: 2011- Implementation at Indian Rayon

In July 2014, the management decided to implement the ISO 50001:2011 Energy Management System to improve its energy performance. A certifying body, DNV, was identifi ed, who could work with the company to implement the system. Since the company had a strong team with two decades of experience in Management Systems, no consultant was engaged for documentation; however, training and certifi cation were within the scope of DNV. With the guidance of

Figure 1: Indian Rayon’s journey towards implementation of Management Systems

Energy Management System: A Holistic Approach for Energy Performance

Table 1: Main Products and Manufacturing Capacities

Product Capacity Integrated Operation

VFY 54.5 TPD

Sodium Sulphate 32 TPD

Sulfuric Acid (H2SO4) 100 TPD

Carbon di Sulfi de (CS2) 27 TPD

Power 34.5 MW

Caustic 250 TPD

1980

1985

1990

1995

2000

2005

2010

2015

2020

ISO 9002 WCM Practices

ISO 14001 OHSAS 18001

SA 8000 Behaviour Base Safety

Process Safety and Business

Excellence

ISO 50001


the Unit Head, a core team was formed under the leadership of FH (QA&TS) who was also appointed as Management Representative for ISO 50001:2011. The core team consisted of:

Function Head (Caustic and Power plant)

Department Head (Finance and Accounts)

Department Head (Power Plant) – also Energy Manager

Department Head (Caustic Plant)

Department Head (Technical)

Section Head (Daily Report)

Section Head (VFY Electrical)

Apart from the core team, an execution team was also formed with members from different sections of the plant. The responsibility of the core team was to review the progress, whereas the execution team was responsible for data collection and documentation.

Implementation plan:

A detailed implantation plan was established by the Management from August 2014 to April 2015 to execute all the activities.

The implementation started from August 2014 by finalizing the certifying body and the first training program was

conducted for team members on 11th October 2014. Thereafter, a two- day internal auditor’s training program was also organized for a team of 20 people during 13th-14th November 2014. The first stage document audit was carried out by DNV during 13th to 14th March 2015. Corrective actions on the first stage audit findings were completed with 15 days. An internal audit was carried out from during 6th - 9th April 2015 and thereafter, a management review was carried out on 11th April 2015. Review of documentation and preparedness for final audit was carried out by DNV from 13th to 14th April 2015 and recommended for final audit which was conducted from 28th to 30th April 2015. After the audit was successfully carried out, certification was recommended for Indian Rayon. Dedication and the involvement of the team made implementation in a short period possible without a consultant.

Action Initiated During Implementation Process: Energy manual established as per ISO

50001:2011 requirement Energy policy documented and

communicated to team Procedures such as energy review,

energy base line, monitoring and measurement method defined

F1 F2 F1 F2 F1 F2 F1 F2 F1 F2 F1 F2 F1 F2 F1 F2 F1 F2Plan

ActualPlan

ActualPlan

ActualPlan

ActualPlan

ActualPlan

ActualPlan

ActualPlan

ActualPlan

ActualPlan

Activity Schedule for implementation of ISO 50001(2011) - Energy Management System

S.No. Activity Responsibility Plan

MonthAug-14 RemarksMar-15 Apr-15

1 To get the quotation from various party D. P. Chouksey

Sep-14 Oct-14 Nov-14 Dec-14 Jan-15 Feb-15

2 Commercial and technical discussion and negotiations with the party

Samir Kapoor / D. P. Chouksey

3 To make the proposal and get the approval from Unit head D. P. Chouksey

4 Form a core members team with leader to initiate for the project Mgmt.

5 Organize the Implementer course on (EnMS)” D. P. Chouksey

6 Vision / Energy policy of the organization and review of existing energy condition Core Team

7 Plan to visit any ABG unit where EnMS is already implemented to understand their process A. B Sojitra Ajay M and DPC visited Nagda on 24~25

Nov.14

7 Preparation of EnMS Manual, Procedures, Work Instructions, formats etc Execution Team Required documents have been made and

ciruclated among the team on 14.12.14

8 Identification, interpretation of all energy oriented legal requirements, preparation of legal register Execution Team

Legal register is already there

9 Review of existing energy condition to identify Core Team

ActualPlan

Actual

PlanActualPlan

ActualPlan

ActualPlan

ActualPlan

Actual

PlanActualPlan

ActualPlan

Actual

Prepared By : D. P. Chouksey Approved By : A. B. Sojitra

11 Based on the review and assessment of the existing energy performances, corrective actions to Core Team

9 significant energy uses, find out OFI and Action Core Team

10 First Stage review audit (Review of the documents) By Certifying body1st stage review audit carried out on 09~10 Mar'15. This process was delayed about 1.5 month due to auditors date

14 Management review MR

15 Data analysis after implementation of the documented system Core Team

Management review carried out on 11-Apr'15

Done, further action plan is to be prepared and the projection for next year by concern department

12 Internal Auditor Training program (2 days) MR Internal Auditor progoram conducted from 13~14 Nov'14

13 Internal Audit planning and execution D. P. Chouksey Internal Audit carried out from 06~09 Apr'2015

18 Issue of certificates By Certifying body Certficate received on 20.06.2015. Congratulation note sent to all

16 Review of all documentation and checking preparedness for Certification audit By Certifying body

17 Audit of the implemented system as per the standards By Certifying body

Audit carried out from 13~14 Apr 15

Audit carried out from 28~30'Apr'15 and Recommended for the certificate

Table 2: Action Plan for implementing the ISO 50001 Energy Management System

Awareness Program – 11th Oct’14

Internal Auditor Tr. Program 13-14 Oct’14

Internal awareness program Feb-Mar’15

Management Review – 11th Apr’15

Stage 1 Audit 13th - 14th Apr’15

Final Audit – 28th Apr’15


Mr. H. S. DagurUnit Head, Indian Rayon, Veraval

“Energy performance is the key factor in sustainable development, ISO 50001 will defi nitely add value towards our journey to excellence.”

Mr. D. R. KamatJoint President Caustic & Power PlantIndian Rayon, Veraval

“Development and increased human activities have signifi cant impact on global environment, economy and society. Hence energy management system ISO 50001:2011 is an eff ective tool to address climate change issue.”

Mr. A. B. SojitraAVP (QA & TS) – VFYIndian Rayon, Veraval

“Energy is the most important part of our daily life and availability of the resources is depreciating day by day. ISO 50001 is one of the steps towards journey to excel in energy performance.”

Format for energy monitoring, change in facility, opportunity register, etc., established

Energy profi le, current energy consumptions trend and comparison with past data documented

Energy review carried out for all the processes

Signifi cant energy consuming process identifi ed and action plan initiated

Baselines established for all processes

Training and awareness down the line on regular basis established.

Annual Energy Consumption Trend

Challenges Faced during implementation

In the absence of a consultant, documentation and establishing of various processes was challenging, but the strong internal team with experience indocumentation helped. An Energy Management System cannot be eff ectively implemented without the involvement of bottom line people and the plant is manpower intensive; three plants at one place made the process little diffi cult. Awareness programs and campaigns helpededucate people and encouraged them to participate actively.

Benefi ts of ISO 50001: 2011 Improved understanding within the

team Focus on micro level projects which

could enhance productivity Improvements in monitoring and

measurement Involvement of the team Reduced power consumption Achievement of PAT targets.

15000

16000

17000

18000

19000

20000

2012-13 2013-14 2014-15

16657

17965

19181

Figure 2: Annual VFY Production (MT)

3000

3500

4000

4500

5000

5500

2012-13 2013-14 2014-15

5485

4892

4061

Figure 3: VFY-Power Consumption (Kwh/T of Yarn)

6.006.507.007.508.008.50

2012-13 2013-14 2014-15

8.458.09

7.13

Figure 4: VFY- Steam Consumption (Million Kcal/T of Yarn)

50000

70000

90000

2012-13 2013-14 2014-15

88334 8677179687

Figure 5: Annual Caustic Production (MT)

1960

1970

1980

1990

2012-13 2013-14 2014-15

19821979

1968

Figure 6: Caustic Power Consumption (Kwh/T of Production)


Best Practice Case Studies

JK Paper Limited, Unit: JKPM, Jaykaypur

– Mr. P.K. Suri, Executive Vice President (W), JK Paper Mills, Rayagada

JK Paper Ltd, Unit: JKPM is among India’s foremost paper manufacturers. It is part of one of India’s leading business houses, the JK Organization. JKPM was commissioned in 1962 with an installed capacity of 18,000 TPA of finished paper. It was expanded in stages and its present capacity is2, 95,000 TPA of coated and uncoated paper. Technology has been upgraded in all areas with new projects, in 2011-2013. Updated technology has helped achieve energy efficiency with capacity enhancement. New projects use state-of-the-art technology in the fiber line, paper machine 6, power block, A4 converting and packaging line, etc.

The primary raw materials used are hard wood and bamboo. JKPM is an integrated pulp and paper mill with a chemical

recovery boiler, high-pressure based circulating fluidizedbed Combustion (CFBC) coal fired boiler (110 ata) and power block (55MW capacity) which meets its electrical energy requirements completely. The plant has FSC certification and also ISO9001, ISO14001 and OHSAS18001 certification.

Specific energy and specific water consumption in the plant from 2012-2015 is shown in Figure 1 and 2.

A significant reduction in the specific energy and water consumption in 2014-15 was achieved by stabilizing new facilities and phasing out of the old pulp mill, old recovery boilers, old coal-fired Atmospheric Fluidise Bed Combustion (AFBC) boilers, and alow-pressure based old power block.

JKPM is continuously identifying opportunities for energy saving through internal and external energy audits and by creating awareness among employees.

Major areas in which energy efficiency has been improved

The new pulp mill has a continuous cooking process and uses a DD washer for multi-stage washing, and blow tanks without agitators. The layout of the plant is compact and operates at medium consistency so as to conserve chemicals and energy. The latest automation has been introduced in processes and an efficient heat recovery system from bleached effluents is in place.

The new recovery section is provided with single, large energy efficient units (evaporator and recovery boiler). The main features are an Heavy Black Liquor (HBL) concentration of >75% solids for higher steam generation at a higher pressure of 65 bar and 450°C, compact filtration equipment in place of clarifiers for improved dryness of lime mud,>70%, improved white liquor sulphidity, clarity<20ppm and Total Active Alkali (TAA). With the new chemical recovery section in place, the share of green power generation from black liquor has increased from 38% to 59%.

The new VOITH paper machine 6 has the following state-of-the-art features: head box without recirculation, single nipco flex shoe press for higher sheet dryness (>50%), vacuum blower, efficient hood and PV system, closed fresh water circuits and efficient back water recycling system, cascade steam and condensate system for efficient heat recovery.

The new power block consists of a single high efficiency 165 TPH CFBC boiler (110

0.68 0.64

0.49

0

0.2

0.4

0.6

0.8

1

2012-13 2013-14 2014-15

Total Specific Energy Consumption (2012-2015), Gate to Gate

toe/t of

paper

Before expansion Transition phase After expansion and phasing out of less energy

efficient facilities

Figure 2: Total specific water consumption in the plant (2012-2015)

68 64

44

0

20

40

60

80

100

2012-13 2013-14 2014-15

Specific water Consumption (2012-2015)

After expansion and phasing out of less energy

efficient facilities

Transition phase Before expansion

m3 /t of

paper

Figure 1: Total specific energy consumption in the plant (2012-2015)

Figure 2: Total specific water consumption in the plant (2012-2015)

Newsletter Issue-5, AprIl, 20168

kg/cm2 and 540°C), high-pressure based cogeneration system (combined heat and power) for enhanced energy efficiency, and centralized centrifugal compressors.

Innovative Project: Heat recovery from bleach plant effluents

Introduction

The bleaching process removes color from the pulp (due to residual lignin), by adding chemicals to the pulp in varying combinations, depending on the end use of the product. The same bleaching processes can be used for any of the pulping process categories. The most common bleaching chemicals are chlorine, chlorine dioxide, hydrogen peroxide, oxygen, caustic, and sodium hypochlorite. Concerns over chlorinated compounds such as dioxins, furans, and chloroform have resulted in a shift away from the use of chlorinated compounds in the bleaching process. Bleaching chemicals are added to the pulp in stages in the bleaching towers. Spent bleaching chemicals are removed between each stage in the washers. Washer effluent is collected in the seal tanks and either re-used in other stages as wash water or sent to wastewater treatment. These bleach plant effluents can contain a large amount of heat, which will be wasted if the effluents are discharged without heat recovery.

Need for innovation

Large amounts of heat were being lost resulting in a heat load on the effluent treatment plant’s (ETP) cooling towers, due to discharge of acid and alkali effluents at a temperature of 75-80°C from the old pulp mill. The Total Productivity Management(TPM) methodology was used to bring about this improvement: a structured PDCA (plan-do-check-act) cycle was followed.

Actions taken

The project to bring in innovations was finalized after measuring heat losses and calculating savings accruing from a heat exchanger to recover heat in the new pulp mill.

A plate-type heat exchanger was selected

and installed. This type of heat exchanger uses metal plates to transfer heat between two fluids and has a major advantage over other conventional heat exchangers, because the fluids are exposed to a much larger surface area. This facilitates the transfer of heat, and greatly increases the speed of the temperature change.

Trial and implementation

The design of the acid and alkali plate-type heat exchangers was based upon the total recoverable thermal energy. The warm water generated by these heat exchangers is used in the plant; initially the warm water generated was used in the pulp mill only but later it was also supplied to the DM plant.

There were no major problems while implementing this project.

Impacts and Benefits

The warm water generated has a temperature around 50°C hence reducing the consumption of steam inthe pulp mill hot water heaters and in deaerators of the chemical recovery boiler.

Overall,the specific steam consumption in the pulp mill was reduced by 25%: details are given in Table 1.• Energy savings: Energy savings

achieved per annum were 7722 toe, i.e. 22013 MT of equivalent coal

• Financial implications: The total amount of money invested in the project was about Rs. 20 million.

• Payback period: The payback period is short, at 3 months, which makes the project attractive for replication

This project is replicable in all pulp mills

by installing heat exchangers (after taking bleach effluent characteristics into account).

Table 1: The specific steam consumption in the mill after the innovative project

Description Acid effluent Alkaline effluent

Inlet temperature, °C 75 80

Outlet temperature, °C 50 52

Temperature drop, °C 25 28

Flow, m3/day 6000 3000

Heat gained by fresh water, million kcal/day 150 84

Heat gained by fresh water, million kcal/year 49500 27720

Mr. Pawan Kumar Suri Executive Vice President (Works), Unit: JK Paper Mills, JK Paper Limited, Jaykaypur

“At JKPM Energy conservation is a way of life. To achieve this, JKPM updates its technology to improve energy efficiency by taking numerous initiatives with internal resources as well as from external experts.”

Acid Effluent Cooler

Alkaline Effluent Cooler



Nectar Lifescience Limited

– Mr. Harparkash Singh Gill, President (Operations & Director) Nectar Lifescience Limited

Introduction

The processing of Cefroxime Acid Axetil Crystalline requires low temperatures at two stages in its three-stage manufacturing process; liquid nitrogen is used to achieve the low temperatures. The reactors in both the steps have limpets as well as jackets. Liquid nitrogen used in limpets is vented out and escapes to the atmosphere at a low temperature of -30°C to -80°C resulting in loss of energy; other solvents and product vapours are also lost alongside. Equipment located nearby can be corroded by these vapours, too. Liquid nitrogen cools rapidly, but the system consumes energy inefficiently and is associated with a loss of liquid nitrogen by vaporization. It was a challenge to attain the low temperature in approximately the same time, using some other means.

About the plant

Nectar Life science Limited (NLL)manufactures Lactam-based antibiotics. It is a knowledge driven organization and a vital part of the Indian pharmaceutical industry. In a short span, NLL has been ranked 365th among the top 500 Indian corporates and is currently among the top 25 forerunners of the Indian pharmaceutical industry; it is ranked 5th in the Indian Bulk Drug Industry from the perspective of stand alone

Active Pharmaceutical Ingredients (API Manufacture).

Energy Consumption

The company’s top priority is minimizing energy consumption by consistently optimizing operating/process parameters, modernizing/upgrading its plants/equipment. The main sources of energy are biomass, HSD and electricity. The company has 100 % self-sufficiency in meeting electric power requirement.

Innovative Project: Refrigeration for Manufacture of Cephalosporin

Mechanical Refrigeration System Coupled with Lithium Bromide Vapour Absorption System: In order to achieve a temperature of -65°C in the process, a system was conceived with -70°C evaporating temperature, keeping in view the following:

a) Energy efficient system with minimum power (kW) requirement in generating one ton of Refrigeration (TR)( kW/TR)

b) Choice of refrigerant

c) Since there was no evaporator, the reactor limpet coil and jacket were used(as evaporator) with surface area a limitation, given the reactor’s geometry and capacity.

d) To achieve the required temperature within the stipulated time, the optimum circulation rate had to be fixed ruling out the possibility of conventional brine cooling.

e) Optimal capital cost by opting for a single system, since there were two different steps with different process parameters and using one system to serve both was a challenge.

f ) Capacity synchronisation within two stages – high stage and booster – to avoid hunting.

g) Choice of system – liquid overfeed and evaporative.

Mechanical Vapour Compressor System Using Two-Stage Screw Compressor, with Lithium Bromide Vapour Absorption System in Third Stage

In order to optimize energy usage, a LiBrvapour absorption chiller was chosen to generate chilled water for condensing ammonia gas. In order to take advantage of the cogeneration plant, a 150TR LiBrchilled water plant was chosen with a steam consumption of 650 kg/hr. This quantity of steam is capable of generating 75 kW of power. Considering the cost of steam at Rs. 1.13/kg (from the multi-fuel boiler), the total cost of steam would be Rs. 675. The power available would be 75 kW per hour, which is equivalent to Rs. 545, at the existing imported electricity cost from the grid (@Rs.7.25 per kWh).Therefore, to generate 150 TR from LiBrvapour absorption chiller, 650 kg per hr steam is required, costing Rs.675/ hr. Simultaneously, 75 kWh of electricity is generated using this steam in a cogeneration system, which results

Table 1: Power consumption and energy consumption trends from 2013-2015

Description Unit 2013-14 2014-15

Electrical energy lacs kWh 281.1 324.2

Production tonne 1306 1824

Power consumption kWh/tonne 21519 17774

Thermal energy consumption million kCal/year 178767 198037

Specific thermal energy consumption

million kCal/tonne 136.88 108.57


in saving of Rs.545 per hr on the imported electricity cost. Therefore overall net cost in favour of LiBr system (150 TR/hr) will be Rs. 130 per hour. It implies to generate 1 TR from LiBr with a cogeneration system, operating cost works out to be Rs. 0.86 per TR (130/150) in comparison to a Screw chiller (requiring 0.8kW/TR) which will cost Rs. 5.80 per TR @Rs. 7.25 kWh tariff of imported electricity

Ammonia was chosen as the refrigerant for the following reasons:1. Low cost of NH3

2. Low capital cost3. Easily detectable leaks4. Lower circulation rate.

Ammonia refrigerant systems have smaller mass flow compared to those using R-22 and R-134a; for example, a 100TR plant for -25°C/+40°C requires 1193 kg/h of ammonia compared to 8317 kg/h of R-22,implying that the pump required to circulate ammonia would be smaller, too, and less power would be consumed.

The comparison of the performance of R134a and ammonia in the liquid overfeed system suggests that due to the better thermodynamic properties of ammonia, the evaporator refrigerating capacity is higher for ammonia and it needs less mass flux than R134a. (Ammonia has a high latent heat of vapourisation so, for equal heat removal, much less ammonia mass needs to be circulated compared to halocarbons).Please see Figures 1 to 6.

Use of brine as a cooling medium to chill the reaction mass in the reactor was ruled out since an evaporating temperature of -70°C would give chilled brine in the range of -60°C to -65°C, and it would not be able to pull down the temperature of the reaction mass to -55°C: if it did, too much time would be needed. For these reasons, the possibility of using a reactor with limpet coil and jacket for ammonia liquid feed circulation was explored, automating the back pressure of the suction line by picking a temperature signal from the reaction mass. An LP receiver was integrated into the system to take care

Figure 1: Compressor Discharge temp. with Heat Source Temp.

Figure 3: Motor Capacity with Heat Source Temperature.

Figure 5: Compressor Mass Flux with Heat Source Temperature.

Figure 2: Compressor Pressure Ratio with Heat Source Temp.

Figure 4: CPD with Heat Source Temperature.

Figure 6: Pump Mass Flux with Heat Source Temperature.

of the fluctuating loads of two reactors working with different parameters at the same time, and to take care of the exothermic nature of the reactions.

Most designers/users feel that the higher the pressure, the better the pump flow to the evaporator/cooler and the better the performance; however, this could

be incorrect. The inlet pressure to the evaporator should be just enough to overcome the pressure drop inside the cooler and the wet refrigerant return line up to the LP vessel. To illustrate, if the plant has been designed for an evaporating temperature of -32°C, the saturation pressure corresponding to -32°C is 1 bar absolute. If the pressure at the inlet


is higher, say 2 bar, the corresponding saturated evaporating temperature is -18°C. This means although the liquid supply temperature is -32°C, it would not evaporate till the pressure inside the evaporator drops to 1 bar (Figure 7).

Circulation Rate

The performance of a refrigeration system is interlinked with the load pattern, and this cannot be met with instantaneously. However, pump circulation decouples the refrigeration system from load variation, acting as a buffer. The liquid overfeed means more circulation of ammonia liquid in the evaporator (in our case the reactor jacket/ limpet coil) is more than the liquid actually vapourising. Excess liquid means overfeed with liquid over feeding. Vapours

coming out of the evaporator are close to saturated conditions without superheat, resulting in lower temperature at the compressor inlet, which corresponds to lower discharge temperature resulting in better and stable performance.

In this article, the terms used are overfeed rate, overfeed ratio, recirculation ratio, circulating number, circulating rate, etc. However, despite the lack of agreement on a single term, the definition of the concept remains the same in textbooks and handbooks.

Will Stoeckers, Industrial Refrigeration Handbook, p302, defines circulation ratio as Refrigerant flow rate supplied to evaporator

Circulation ratio, n=-----------------------------------------------

Flow rate of refrigerant vaporized

ASHRAE Refrigeration Handbook, 1990, p2.3, states: “In a liquid overfeed system; the mass ratio of liquid pumped to the amount of vaporized liquid is the circulating number of rate”.

The circulation ratio defines the quality of the refrigerant at the outlet of the evaporator. If the vapour quality is 50%,

circulation ratio is 2:1 and if the vapor quality is 33%, it is 3:1. Note that these definitions do not distinguish whether the work done by the evaporating refrigerant is useful or non-useful. It is a simple ratio between the amount of vapour generated and the amount of liquid fed to the evaporator.

There are no clear-cut guidelines and explanations as to how to decide the circulation rate, and the designer has to establish it based on his experience and system parameters.

The heat transfer coefficient increases as the circulation rate increases. Please see Figure 8.

The largest gain in heat transfer is when the entire inside of the evaporator area remains completely wet from inlet to outlet, as it is the latent heat transfer or phase change process which absorbs the maximum amount of heat from the fluid or product. A circulation rate of 1:6 was designed, with a bypass line for adjusting the circulation rate. This resulted in better heat transfer, optimum power consumption and the desired temperature being attained in the desired time.

The liquid recirculation system is the most advanced and energy efficient technique in ammonia refrigeration terminology. The ammonia liquid from surge drum (accumulator) is forced circulated in the evaporators of cold storages, or freezer, blast freezers air-cooling units through liquid-feed-pumps. For multiple cold rooms and freezers it is supposed to be the best choice to save electric energy as well getting the highest efficiency of the refrigeration systems.

Figure 7: Pressure with Distance along Evaporator.

Refrigeration plant room for compound ammonia chilling at minus 70°C

Figure 8: Overall Heat Transfer Coefficient with Circulation Ratio.


The advantages of ammonia liquid recirculation are as under:

a) Increase in efficiency: The internal surface of cooling coils (evaporator) is completely wetted and therefore provides much better efficiency of the refrigeration system. The internal surface of cooling coils (evaporator) is the completely wetted and therefore provides better efficiency of the refrigeration system.

b) Compressor protection: The compressors are protected from liquid slugs resulting from malfunctioning of multiple units.

c) Lower discharge pressure: Low suction superheat causes minimum discharge temperature and minimum condenser fouling.

d) Accumulator not needed: There is no need for individual accumulators for every evaporator.

e) Increase in compressor life: Because of ideal entering suction gas conditions, lower compressor maintenance and fewer breakdowns, compressor life increases. Oil circulation rate to the evaporators, discharge superheat and separation at the surge drum are reduced.

f ) Overall benefit: Liquid recirculation systems are most useful for multiple users, e.g. two reactors working at different chilling parameters. In the present case, higher velocities have been maintained in limpet coils resulting in better heat transfer and better temperature attainment timings compared to liquid nitrogen, due to less time taken to cool the mass in the reactor by ammonia circulating in limpet and jacket with higher velocity. Circulation ratio of 6:1 was less than the liquid nitrogen utility, since liquid nitrogen was vaporizing in the limpet coil and heat transfer was inferior to liquid over-feed. There was saving of nearly 1.30h for a 6 KL reactor mass chilling for the same process conditions.

In order to synchronize and take care of fluctuations as well as part loading and energy conservation in addition to capacity control through the slide valve getting a signal from PLC, VFDs with compressor motors were also employed resulting in better synchronization of high stage compressor with booster compressor and lower energy consumption as well as no hunting on part load.

Brief Working Principal

The HP receiver acts as a storage vessel in which ammonia gas is charged, which works at 15°C and 6.39kg/cm2g pressure. High pressure ammonia liquid from the HP receiver feeds the LP receiver after sub-cooling through the intercooler (liquid and gas cooler). The sub-cooling is done by the partially filled liquid in the intercooler shell, which enters from the HP receiver after expansion at -40°C.

From LP receiver, liquid ammonia pump delivers ammonia liquid to the reactor vessels with a circulation ratio of 6:1. The LP vessel performs two major roles in the system:

I. Liquid vapour separation to ensure only vapour is sucked by the compressor.

II. Liquid refrigerant storage at the required temperature so that it is available as a utility to meet the requirement of either one or more operating evaporators.

Figure 9: Flow Diagram for minus 60 deg C NH3/H2O cascade system

In the reactor vessel, heat exchange occurs between ammonia liquid and the chemical, due to which the liquid changes into vapour, and the vapour, containing liquid and gas molecules of ammonia returns to LP receiver.

The low stage compressor sucks the dry gas from the LP receiver at 0.8 bar (vacuum)pressure and delivers the superheated gas at 0.28 bar(vacuum).

This superheated gas goes to cooler where de-superheating occurs to reduce the compressor work done.

The high stage compressor sucks the dry saturated gas from the cooler at 0.28bar(vacuum), and delivers the high temperature gas at 6.28bar pressure.

High temperature ammonia gas condenses to ammonia liquid at 15°C temp by exchanging heat with the chilled water which enters in the condenser at 8°C and leaves at 12°C, with flow rate of 90.8cmh.

Now this condensed ammonia liquid at15°C goes to the HP receiver, and the cycle restarts. Please see Figure 9 for a flow diagram for-70°C.

Optimum Flow Rate Adjustment

The system is provided with flow regulating valves at the inlet of jacket and limpet coil of reactor,and automatic flow regulation serves two functions. It adjusts the flow of liquid ammonia, and


1. Reactor vessel should be designed for 300 psi for the shell as well as jacket side. 2. Reactor shell should be fabricated from SS316 grade; for limpet, SS316/SS304 should be used.3. Jacket should be designed for 300 psi,and constructed ofa material suited to a low temperature application. 4. Safety valves should be provided in the jacket and limpet side to vent out excess pressure being developed during long shutdowns. 5. LP vessel should be designed for 300 psi since long or accidental shutdown may lead to increase in pressure. 6. High-level alarm should be set at 50% level and shut down at 55% level. 7. Suction pipe to pump should be sized with 3 fps velocity. Ball valves in pump suction are best to givefull flow.8. Pump should be at least 6 pipe diameters away fromelbow, and eccentric reducers at the pump flange are recommended when

direct vertical inlet to pump is not possible. Preferred piping is always vertical direct inlet to pump suction.9. Pump mounting places should be supported on flexible mounts to accommodate piping length variation due to temperature

variation.10. Oil drain pot should not be insulated and a pressure relief valve must be provided for the drain pot.11. Vortex breaker should be provided in the inlet line of liquid to pump in the LP receiver.12. Pumps should be selected for low NPSH (1.5 to 2.5 ft head). Liquid level from centre-line of pump suction to ammonia operating

level should be twice the pump NPSH.13. Provide independent suction pipe to each pump and not from common drop leg, if possible, to ensure that vapour bubbles caused

by heat transfer from standby idle pump to suction of operating pump are avoided.

Box 1: Some useful tips

Table 2: Energy savings achieved in this project

Liquid Nitrogen procured /annum for oral H plant per cubic meter 5309174

Cost of liquid nitrogen per cubic meter 7.25

Cost of liquid nitrogen per annum 38491511.5

After replaced with mechanical system, it runs on average 8 hrs/day

Power consumed/day in KWH as per log book 900

Power consumed in Rs /annum 2123550

Chilled water generate through VAM in Rs per annum 2138400

Saving/annum in Rs 34229561.5

Figure 10: Present of Capacity with Circulation Ratio.

Figure 11: Overall Heat Transfer Coefficient with Circulation Ratio. 1000 is provided in the liquid mass inside

the thermowell. The flow regulating valve is adjusted as per 4≈20 mA Signal from Pt 1000 temperature controller. The inlet pressure to the coil/jacket is adjusted to overcome the pressure drop across the reactor jacket/limpet and wet refrigerant line up to the LP receiver. Please see Figures 10 and 11.

Feed Section (Top or Bottom)

When feed rate increases, velocity increases. For better efficiency, bottom feed is preferred to top feed where higher

velocity would cause a lot of splashing and may result in some un-wetted portions in the total evaporation area. Liquid separation is unlikely to occur in the bottom feed, since the liquid is being pushed up violently by gas molecules vibrating at sonic speed. Although ASHARE recommends a circulation rate of 1:2 to 4 for bottom feed, a circulation rate of 1:6 was chosen since the application was typical with limitations of surface area,time and exothermic nature.

also acts as a check valve for both of the reactors under positive temperature and under pull-down conditions. In order to adjust the flow temperature,probe Pt



BILT Graphics Paper Products Limited, Unit: Ballarpur

– Mr. Sunil Sapre, GM (Engineering), BGPPL, Ballarpur

Brief about the Plant

BILT Graphics Paper Products Limited, (Unit Ballarpur), India, is one of the largest manufacturers of uncoated wood-free/industrial grades of paper and market pulp. The unit makes a large range of products in note book printing, map litho/ publication, azure laid, industrial packaging and industrial tissue, with paper machines ranging in capacity from 25 TPD to 520 TPD. The Ballarpur unit started operations in 1953 with a single 25 TPD machine. After commissioning the new PM-7 by Allimand, France, with a capacity of 520 TPD in 2009, the installed paper production capacity of the unit increased to 2,99,550 MT/annum. This unit pioneered the manufacture of a wide range of high quality writing / printing and industrial grades of paper for a variety of prestigious end users, and has been doing so for the last 62 years. In 2013, a new pulp mill (900 TPD capacity) was commissioned, incorporating the latest technology: continuous digesters, ODL process technology with ECF bleaching meant that the company would have an edge in the market in terms of environmental performance, energy consumption and quality. Simultaneously, India’s largest soda

recovery boiler with capacity 1650 TPD solid fi ring was commissioned. With the above-mentioned expansion activities over the last 6 years, Unit Ballarpur now is one of the largest integrated pulp and paper manufacturers with 7 paper machine lines and a captive pulp production facility which also caters to the pulp requirement of sister concerns at Ashti and Bhigwan.

Unit Ballarpur is the first in the integrated Pulp & Paper category to implement and get certified in the ISO 50001 Energy Management System. It is also an ISO 9001, 14001, 18001 and FSC-COC and CW certified unit, ensuring better quality, environment, safety and authenticated sourcing of raw material. It is the first integrated Pulp & Paper unit in India to have commissioned Dissolved Air Filtration (DAF) along with the Moving Bed Biofilm Reactor (MBBR), both of which are patented technologies, from Ovivo Finland, to enhance environmental performance and modernize the pulp mill.

Innovative Project: Stopping one MC pump of motor rating 315 KW to avoid double pumping after Oxygen Delignifi cation (ODL).

050000

100000150000200000250000300000350000

13-14 14-15

25319

311137

MT CO2e

0

50

100

150

200

13-14 14-15

67

161

Electrical savings,Lac Kwh

0

100000

200000

300000

13-14 14-15

7898

275850

Thermal Savings, Million Kcal

Table 1: Energy Consumption in the Plant (2012-2015)

Description Unit 2012-13 2013-14 2014-15

Annual production (please specify products)

Metric tonne 247088 246898 241192

Total electrical energy consumption/ year

Million kWh 442.5 429.8 374.6

Specifi c electrical energy consumption kWh/t 1791 1741 1553

Total thermal energy consumption (used only for process and not for power generation and as a raw material)

Million kcal 1177 1158.7 957.8

Specifi c thermal energy consumption Million kcal/t .0047 .00469 .0039

Figure 1: Energy savings and GHG mitigation achieved

Problem necessitating introduction of innovation.

A new fi ber line with continuous cooking with ECF bleaching of 900 TPD Air Dried (AD) bleached pulp was commissioned in 2013. Oxygen delignifi cation is an environmentally friendly process in which lignin is reduced after cooking; this cuts down the consumption of chemicals used for bleaching and also reduced load on the effl uent treatment plant (ETP).

NEWSLETTER ISSUE-5, APRIL, 2016 15

There are three stages of pulp washing before ODL, and two stages of pulp washing after ODL. The stages before ODL are, washing in cooking diff user, double decker and TRPB Press, and the ones after ODL are washing in ODL diff user and dewatering press.

Washing in the DPA press was good compared to ODL diff user, discharge pulp consistency from DPA press was 30-32% compared to 9-10% from ODL diff user.

There was no remarkable reduction in COD level when the ODL diff user was in line and there were also operational problems because of which the ODL diff user had been bypassed for a year and a half.

The ODL diff user, feed and discharge MC pumps were running even after bypassing the ODL diff user, wasting power because of double pumping.

Technology adopted

The fi ber line team questioned the necessity of running the feed and discharge pumps for diff user operation since it was not aff ecting either to the volume of the pulp or reducing the chemicals used for bleaching. Diff erent ways of reducing net power consumption

in the system such as installing two smaller pumps, installing variable frequency drives on both pumps and stopping the pump were explored. Finally, the least expensive option, that is, option of stopping the discharge pump was used in the trial.

Methodology adopted Line modifi ed to connect diff user feed

MC pump delivery line to discharge line.

Additional on/off valve provided to operate from DCS.

Two manual valves (one 24 inches and one 10 inches in diameter) were provided for isolation.

Diff user feed MC pump vacuum fl ushing line modifi ed.

ODL diff user discharge MC pump of motor rating 315 kW stopped successfully.

Actions Taken

Following process was adopted during the inception, engineering, implementation and monitoring of gains during the project.

Cross-functional team formation

Data collection

Weekly meetings

Identifi cation of possible causes of problem reasons and plotting on fi sh bone diagram

Data analysis

Identifi cation of activities, micro activity chart

Execution of work

Measurement and verifi cation of operational / fi nancial gains.

Problems faced during implementation

During trials, the MC pump was discharging the required pulp stock of 10% consistency because of an inadequate vacuum. The size of the vacuum line was increased after which the pumps worked to full capacity.

Trial & Implementation period

As per the plan, modifi cations to the pipeline network including connecting the diff user feed MC pump delivery line to the discharge line, vacuum fl ushing line for diff user feed MC pump, installing an additional on/off valve for process control from the DCS and installing two manual valves (24 inch and 10 inch diameter) for isolation, were carried out during a 12-

Pictures before and after implementation


Mr. Ch. Venkateshwarlu CGM Unit, Ballarpur

“The case study showcased here highlights high level of commitment towards energy conservation and an excellent example of team building in Ballarpur team. By imparting TQM & ISO 50001 methodology inputs to shop floor operators, implementation of low cost small improvement ideas has yielded significant savings.

With very low investment of Rs. 3 Lakhs, we have annualized monetary savings of Rs. 40 Lakhs per annum.”

hour shutdown of the pulp mill on the 12th of January 2016.

Impacts and Benefits

Financial Implications: Investments and Savings:

Saving in power by stopping double pumping (315 KW motor stopped)

Reduction in power consumption: 4100 KWH/day (6.5 Kwh/ADT pulp)

Investment Made : Rs. 3.0 L

Savings achieved: Rs. 40 Lac/annum

Impact of the project on the overall performance of the plant

Operation made simple

Pump and motor available for use as spares

Sense of satisfaction

Team of Innovators

The team behind the successful implementation of the project were (L-R front row), Mr. Mr. Raju Wangawar (Operator), Mr. S Pandey (Manager–Mech.), Mr. S.M Patil(Dy. Mgr.-Process ), Mr. G Hasyger( DGM-Process), Mr. T D Thomas(GM-Process), Mr. H Gupta(Dy. Mgr.-Process ), Mr. P Reddy(Manager –Instrumentation), Mr. Satish(Asst. Manager -Electrical).

The team was led and guided by Mr. S K Jain, GM(Engg.) (Right-most picture)

Contribution of the project in achieving the PAT Targets

This project will help to achieve 365 mtoe during PAT.

Contribution of ISO 50001 certification

ISO methodology was adopted by following the PDCA cycle, formation of

small groups, brain-storming and drawing Pareto diagrams during the conceiving, execution and implementation phases.

NEWSLETTER ISSUE-5, APRIL, 2016 17

Trading of Energy Saving Certifi cates

– Mr. Girja Shankar, Assistant Energy Economist, Bureau of Energy Effi ciency

The Perform, Achieve and Trade (PAT) scheme is one of the initiatives under The National Mission for Enhanced Energy Effi ciency (NMEEE), which was notifi ed on 30 March, 2012. The PAT scheme is designed to accelerate the implementation of cost-eff ective measures related to energy effi ciency in large, energy-intensive industries. The PAT scheme establishes a market to achieve twin objectives of fi nancial incentives, thereby reducing cost and compliance with energy effi ciency targets, by certifying energy savings that can be traded.

The fi rst PAT cycle covered 478 designated consumers (DC) in 8 sectors. Considered all together,the reduction in average energy consumption expected was 4.05% by2014-15. This equals a reduction of about 6.686 million tonnes of oil equivalent (mtoe) in their annual energy consumption and a reduction of about 23 million tonnes of carbon dioxide emissions, annually.

Under the PAT mechanism, quantifi ed energy savings are converted into Energy Saving Certifi cates (ESCerts). When a designated consumer achieves and surpasses the target, its excess savings can be sold in the form of Energy Savings Certifi cates (ESCerts); if a designated consumer fails to achieve its targets, it must purchase the appropriate number of ESCerts to meet its energy savings targets. ESCerts have most of the market attributes required for any commodity to be traded.

The Institutional framework for ESCert trading involves the Central Electricity Regulatory Commission (CERC) as market regulator; the Power System Operation and Corporation (POSOCO) as the central

Concept of PAT Mechanism

*Compliance period-Trading: The trading shall be done between the period starting from the last date of submission of the performance assessment document in Form A subsequent to the issuance of Energy Savings Certifi cates and ending on the last date of submission of status of compliance to concerned State Designated Agency with a copy to Bureau in Form D.

*Post- Compliance Period – Trading: The trading shall be done between the period starting after the last date of submission of status of compliance to concerned State Designated Agency with a copy to Bureau in Form D for the current cycle till the last date of submission of status of compliance to concerned State Designated Agency with a copy to Bureau in Form D for next PAT Cycle.

*Non Trading Period: One month from the date of last trading session for each cycle as declared by the Commission and the period from last date of submission of FormA& B to the date of issuance of ESCerts shall be the no trading period.

registry; BEE as scheme administrator; and the Power Exchanges as the market platform. BEE’s D-CRM portal and the PATNet platform will maintain data fl ow and storage. The Commission (CERC) has already prepared ESCert Exchange Regulations-2016, for which the public hearing process has been completed. After notifying these regulations and

approving the procedures of the Registry and Power Exchanges, ESCert trading will be initiated.The frequency of trade, including date and day, shall be as declared by the Commission in consultation with the Administrator from time to time. Exchange of ESCerts will be carried out in two trading period windows as shown in the fi gure below.


– Dr. B.P. Thapliyal, Scientist, Central Pulp & Paper Research Institute, Saharanpur

The Perform-Achieve-Trade scheme in the Pulp and Paper Sector: Challenges and Achievements

Energy is an essential input and its supply forms the largest component, 20-30%, of costs in paper manufacture; it is the only variable which can be controlled to make the paper industry cost competitive. The pulp and paper sector is thus one of the eight energy intensive sectors notified under the PAT scheme with specific energy saving targets. The first PAT cycle covers 31 notified Designated Paper and Pulp industries which consume 30,000 metric tons of oil equivalent (mtoe) per annum and above. These mills have reported 2.09 million metric tonne of oil equivalent (mtoe) and were assigned an energy reduction target of 0.123 million mtoe in the first PAT cycle (2012-15). The designated consumers in pulp and paper sector have been grouped into different categories based on the raw material and process used, and the final products.

The pulp and paper industry has used the PAT scheme as an opportunity to implement measures to improve energy efficiency. The PAT scheme will encourage the paper and pulp sector

to introduce state-of-the-art clean and green technologies and enhance competitiveness through a market based mechanism.

Significance of Energy Efficiency Improvements in Pulp and Paper SectorThe paper industry is a high priority one, with links to the cultural, societal and industrial development of the country. The use of paper by a society is often taken as a yardstick of its development. After it attained independence, paper production in India grew rapidly from 1.37 lakh tons per annum to 14 million tons in 2014. Although, India is the seventh largest country in the world and has the second highest population, the production of paper and paperboard in India is only 1.6% of the total world’s production. The per capita consumption in India is 11 kg as against 42 kg in China, 22 kg in Indonesia, 25 kg in Malaysia, and 312 kg in the US. This is expected to change in the years to come as the Indian populace adopts an increasingly Westernized life style. The growth of the paper industry is driven by market demand and also depends on the country’s overall industrial growth and literacy. A forecast based upon extrapolating the trends in growth of paper consumption predicts that 16.5 million tons of paper will be used in 2016-17, and 25.3 million tons, in 2026-27.

The Indian paper industry has a highly fragmented structure consisting of small, medium and large sized paper mills. The raw materials most commonly used for manufacturing different varieties of paper, paper board and newsprint are wood, agro residues and recycled /waste paper. In order to meet future demand the Indian

pulp and paper industry must address issues related to raw material resources, infrastructure, capital, etc. Most small and medium mills use old and obsolete machines/technology, thus making upgradation and energy efficiency major issues to be addressed; these issues lead to high costs of production, environmental problems, inferior quality, and lower economies of scale.

Any improvements in energy efficiency brought about by modernizing processes and upgrading technology are capital intensive; therefore the incentive-based mechanism under the PAT scheme will encourage the adoption of state-of-the-art technologies.

Energy efficiency improvements and challenges the sector faces There is much scope for both small and large scale measures; while small measures will result in marginal savings, existing technology must be upgraded in different units to achieve the energy efficiency targets. Environmental challenges are one of the most serious consequences of using outdated technology. There have been remarkable technological developments in the paper industry, particularly in the US and Europe. These have resulted in cellulosic raw materials and chemicals being used more economically, reduced pollution, and have allowed more cost-effective production. Countries close to India such as China, Malaysia, Indonesia and Thailand have kept pace with technological advancements benefitting their paper industry. In India, improved technologies are required in the following areas of the pulp and paper industry:

1. 31 Designated Consumers (DCs) notified in the pulp and paper sector for the first PAT cycle.

2. National Energy Savings Target: 6.686 million mtoe

3. Energy Savings Target for pulp and paper sector: 0.123 million mtoe (1.84 % of total energy savings target)

4. Benefit of Compliance: Issuance of tradable ESCerts (energy saving certificates) per mtoe energy saving achieved above the target set for the plant.

Box 1: The Pulp and Paper Sector in PAT Cycle (2012-15)


Raw material handling, pulping, pulp washing and bleaching

Paper machine

Chemical recovery

Power generation

Effluent load and colour removal

Solid waste management

Air pollution control

Specific processes in pulp and paper manufacture with scope for technology upgradations and energy efficiency improvements exist and a few are briefly described below.

Raw material processing Debarking of wood logs is a standard

practice in mills abroad. However, in Indian mills no debarkers are used as eucalyptus, which is the most used woody raw material, is debarked during cutting, in the forest or on farms. Other trees used as raw material such as poplar and casuarina are chipped and digested with the bark intact. There is need to debark these and use efficient wood chippers and chips screens in wood-based mills. A large number of equipment suppliers of imported and indigenous technology offer a range of equipment to suit the industry’s requirements.

In the agro-based mills,the washing and depithing of bagasse is important from the viewpoint of quality of pulp, and chemical use during pulping and processing of black liquor. Indigenous technologies are available to address these issues and for processing these raw materials. These technologies need to be adopted.

Pulping Most Indian mills use rotary or

stationary batch digesters,while mills abroad use modified systems such as super batch cooking to obtain pulp with better strength, using less steam and chemicals. Leading technology and equipment suppliers offer the equipment required for these processes

and should be implemented by mills. Continuous horizontal digesters should be used in place of conventional rotary batch digesters to process agro residues. Several imported/indigenous equipment suppliers offer these technologies.

ECF Fibreline (washing, oxygen delignification, screening andbleaching) Modern pulp washing technologies

and ultra-filters such as the belt filter, double wire belt washer, twin roll washer and diffuser washers which have the minimum dilution factor and chemical losses, and maximum washing efficiency,should be used to enhance energy efficiency.

In developed countries, oxygen delignification is followed by efficient screening to obtain pulp with a low kappa number (and higher strength) before bleaching. Wood and agro-based mills in India use conventional screening and cleaning systems which are inefficient, result in higher fiber losses, and consume more energy.

Most Indian mills use elemental chlorine whereas mills abroad use the Total Chlorine Free (TCF), or Elemental Chlorine Free (ECF) bleaching which are less polluting.

Chemical Recovery Most Indian mills use long tube vertical

type evaporators (LTV) whereas in mills abroad, evaporation is by full Street of falling film evaporators. Technologies such as thermal treatment for high solids evaporation of black liquor are also used by mills in developed countries.

In Indian mills, most recovery boilers used are small capacity double drum boilers. Single drum, high pressure, high solids, high capacity recovery boilers with advanced control systems are more efficient and are being used in mills abroad. There is need to replace less efficient small recovery boilers with modern ones.

It is necessary to use modern technology for re-causticizing and lime re-burning so as to increase the efficiency of chemical recovery in Indian mills.

Process Control in pulp mill and Recovery Island Distributed Control Systems and online

instrumentation to monitor process parameters are a must for efficient operation and control in the pulp mill and recovery island. Only a few Indian mills have such process control systems.

Stock preparation, Paper Machine and Finishing House Technology upgrades are required

during paper-making operations; some of these are: distributed control systems with automatic metering in the stock preparation and additive section; high speed machines with wider deckles, modern head boxes/ twin wire formers; bi-nip/tri-nip presses; closed hoods; automatic CD profile control systems; efficient condensate removal systems with a combination of soft nip and hard nip calendars;modern vacuum and compressed air systems;and modernized finishing houses to reduce finishing losses.

Captive co-gen power plants Adoption of efficient multifuel high

pressure boilers, turbines and producer gas plants to use biomass as a source of clean fuel, are required to address the energy requirements of the mills.

Modern water treatment and recycling systems Mills need to adopt better effluent

treatment practices enabling more reuse of water, efficient dewatering of secondary sludge by screw press and NCG control systems.

Industry seeks financial support from the Government for the above energy efficiency and modernization initiatives. Incentives under the PAT scheme can help initiate improvements in


themodernization of technology used and energy efficiency measures leading to benefits in several aspects.

Energy Efficiency Measures Adopted by the Pulp and Paper SectorDesignated Consumers in the pulp and paper sector have taken up the challenge to achieve the energy efficiency targets and many mills have made remarkable progress. Out of the large number of measures adopted and reported by the mills, some of the notable achievements are discussed below.

1. Installation of state-of-the-artcontinuous digestersand pulp mills

A pulp mill using conventional batch digesters, and a double drum recovery boilerwas modernized by installing a state-of-the-art continuous digester and a modern recovery boiler. The mill achieved significant savings in specific steam and power consumption, as shown below. Steam in pulping: Reduction from 1.8

ton steam/ton pulp to 0.78 ton steam/ton pulp.

Power consumption: Reduction from 750 kWh/ton pulp to 686 kWh/ton pulp.

Steam economy in evaporator: Increased from4.1 ton steam per ton of black liquor solids to >5.2 ton steam per ton of black liquor solids.

Overall chemical recovery efficiency: Increased from 94.5% to>97%.

2. Modernization in paper machine dryers via the installation of a thermo-

Figure 1: Conventional Batch Digester,(a),and, Modern Continuous Digester, (b)

(a) (b)

Figure 2: Cascade System for Condensate Handling

Figure 3: Thermo-Compressor Based Condensate System

compressor based system to replace the existing cascade system,and rotary siphons with high speed stationary siphons for efficient condensate removal.

In a mill using the cascade system for condensate removal, a thermo-compressor based system was installed

which improved condensate recovery from only 35-40% (due to condensate evacuation problems/leakages) to 85%. Specific consumption of steam was reduced from 3.0 ton/ ton paper to 2.8 ton/ ton of paper in the machine. This also resulted in a reduction of drive load from 259 kW to 204 kW.

The work done by Bureau of Energy Efficiency in implementing the PAT scheme is unique and will help the pulp and paper sector to identify inefficiencies in their processes and initiate plans to increase energy efficiency and adopt measures to improve their overall SEC. The results of the first PAT cycle will highlight the efforts made by the industry in achieving the goals of National Mission for Enhanced Energy Efficiency.


Innovative Technologies to promote Energy Efficiency

Automatic Tube Cleaning System

– Mr. Aashish Sharma, Dy. General Manager – Sales & Business Development , CQM-RAJ

This system is used in power plants for cleaning condenser/heat exchanger tubes fouled by scaling or biological growth.

Condenser tube fouling contributes up to 50% of the total condenser tube heat transfer resistance, reducing heat exchanger performance, production, and increasing operational cost, back pressure, tube failure and maintenance.

The on-line Automatic Tube Cleaning System (ATCS) for condensers and heat exchangers provides a means of automatic cleaning continuously, while the exchanger or condenser remains “on stream” and at its full operating potential. In this method sponge balls are injected into the condenser tube; ball loss does not occur as with traditionally available systems in the market.

Features of the Automatic Tube Cleaning system Excellent cleaning: Continuous on-

line cleaning, reaching all tubes, both central and peripheral.

Accurate control of the cleaning process: Maintains a higher heat transfer coefficient, customizable cleaning intervals provide high performance and minimized ball wear.

Minimum pressure drop: Size of the ball trap is 3.5 times the cross sectional area of the cooling water outlet line size resulting in minimum pressure drop across the condenser.

Simplicity: Delivering high reliability, rapid installation and effortless maintenance with a minimum of mechanical, electrical and control interfaces.

Foolproof ball trap: No ball loss is guaranteed.

The principal types of fouling encountered in process heat exchangers include:

Particulate fouling

Corrosion fouling

Biological fouling

Crystallization fouling

Chemical reaction fouling

Injection water heatersat the exploration terminal heat the injection water (which serves as power fluid and is required for well water lifting).

In oil exploration, experience shows that oil, salts and calcium carbonate are the dominant foulers. Fouling increases overtime, and the trajectory is acute leading to very high DP which necessitates frequent cleaning. The exchangers E-415 A/B & C were designed to accommodate water of a certain composition, but changes in the composition of water used currently has brought about increased fouling resistance which chokes tubes, and increases downtime for cleaning.

The technology supplier (CQM) through studies and field trials conducted over 24 months, has identified the perfect

Wide range of applications: Reduces tube corrosion and tube failure caused by fouling and scalingand suitable for a wide variety of heat exchangers.

Fast ROI: Return on investment is usually less than 1 year.

User Experience: Oil Exploration Company in India

Problem necessitating introduction of technology:

The performance of shell-and-tube type heat exchangers within a process can affect the cost of the final product, or even the production rate. Unfortunately, heat exchangers are prone to fouling, its nature depending on the fluids flowing within and over the tubes;the reduction in heat transfer that results, almost invariably has an impact on product cost. To reduce this impact, heat exchanger performance should be continually monitored and the heat exchanger cleaned at intervals that are determined by the increase in DP and reduced DT across exchangers.

Exchanger tube cleanliness is difficult to achieve using traditional methods including water jetting which often requires multiple passes, thereby extending the duration of a shutdown and resulting in production going into a critical path.


ball geometry and material for this process. According to the original proposal, ATCS were commissioned on the exchangers E-415-A, B & C on a trial basis to overcome the need for manual cleaning. The system was implemented in March 2013 and after brief operation the system was put on standby pending further investigation.

After these initial trials CQM continued with trials at laboratory scale using new ball geometry and alternative materials to check their suitability for the medium, oily water in this case. Finally,a ball made silicone with suitable ball geometry was used in recent trials (starting 14th January 2015) and found to operate successfully. The results are exemplary and are comparable with new exchangers in terms of both maintaining low DPs and a high heat transfer DT consistently at varying fl ows.

The implementation of ATCS over time will off er the following advantages:

Reduce energy consumption by improving heat transfer effi ciency

Reduce costs associated with manual cleaning of the heat exchanger

Reduce downtime and improve availability

Help increase production by meeting the water injection targets

Reduce operations and maintenance costs

Protect and extend the life of heat exchanger

Reduce environmental impact

Challenges:

The customer faced the following challenges which could be addressed by installing the ATCS:

Heavy fouling

Increased cleaning frequency

Severe time constraints leading to loss in water injection and consequential eff ect on oil production.

Progress and achievements to date:

CQM’s online automatic tube cleaning system (ATCS), was used in water injection heaters (shell-and-tube exchangers) E-415-A, B and C in March 2013. After several attempts to optimize the design, the system was commissioned once again on 14th January and a fi eld trial performed under the customer’s supervision.

The current skid arrangement has a common pump and control unit across all three exchangers. The balls are introduced into the system along with the process medium at regular intervals, monitored by the inbuilt PLC system.

The ATCS skid comes with its own pump that helps in fl uidizing the balls stored in the ball collector and for injection into the process stream.

The ATCS operates on injection cycle, collection and restoration cycle. The overall duration of operation is 20 minutes and the cycle is repeated at regular intervals across all three exchangers, that is E-415A/B and C.

The ATCS was commissioned first on unit E-415B on 14th January 2015 followed by unit E-415C on 28th January. The system has been in operation since these

dates and is performing well, with DP and DT in line with the original design conditions.

The ATCS has allowed achieving and maintaining higher DT and lower DP across exchangers E-415 B/C thereby reducing the need for intervention and consistently delivering a higher outlet water temperature required to maintain operational effi ciency. Data collected before and after installation of the ATCS is shown in Figures 1 and 2.

The graphs show that the temperature obtained after installing the ATCS has been in the range of +18 to 21C at varying fl ow rates. When compared to the exchangers without the ATCS the temperature diff erence is lower, in the range of 7 to 8C; the same is observed in data gathered from in exchangers E-415 D/E.

When fouling occurs, the temperature of the heating fl uid must rise if the same amount of heat is to be transferred through the tubes. This temperature rise must be associated either with an increase in the total energy input to the process or a reduction in production rate, both of which represent a cost incurred due to fouling. Clearly, in order to make economic decisions, the costs must be

ATCS in Operation on E-415B & C

Figure 1: Comparison of delta-T across exchangers E-415 A/B/C


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Comparison of DP across Exchanger E-415A/B/C

E-415A-DP

E-415B-DP

E-415C-DP

Figure 2: Comparison of DP across exchanger E-415A/B/C

Economic advantages/savings:Reduction in mechanical cleaning once every 21 days @ US$ 5,000 / every instance across 3 exchangers E-415 A/B/C

US$ 5000 x 18 x 3 = US$ 2,70,000

Increased availability and impact on production at an approximate estimated increase of 3000 BBL of oil equivalent/day for 365 days

US$ 55/BBL x 1,095,000 = US$ 60,225,000

Total economic impact on account of ATCS per year US$ 60,495,000

quantified at a series of points in time and, preferably in relation to the fouling resistance.

Currently, the customer uses DP as the criterion for cleaning the exchanger. The time needed to clean the exchangers varies with the extent of cleaning required. Data suggests that the system has to be taken offline for anywhere between 5 and 7 days at a stretch to achieve a totally clean exchanger.

However, the time needed to clean the exchangers is not uniform because of varying flowrates. The same goes for the downtime required to achieve a totally clean exchanger.

Mechanical means of cleaning such as water jetting or rodding to break the hard scales could reduce the life of the exchanger tubes leading to tube failures and blanking of tubes or replacement of bundle over time. Both the above scenarios are expensive considering the

reduced availability of exchanger for process heating and/or replacement.

The economics of tube cleaning at regular intervals compounded with reduced availability and consequential loss of production is expensive, therefore the ATCS is considered as the best alternative in this case because there is no costly downtime and or mechanical cleaning of exchangers.

Additionally the ATCS needs minimum-to-no intervention and is an automated system which doesn’t interfere with the process.

The methods involved in working out an economic analysis of the ATCS implementation is a time function and given the lack of production data, the summary below is an estimate which needs to be validated.

The above analysis only considers two key factors but there are many more including

savings on account of reduced thermal input, etc., not considered here.

About the technology supplier

C.Q.M., Cooling Quality Management Limited, founded in 1994, is a company with headquarters in Israel.

They are global providers of on-line mechanical anti-fouling solutions. CQM products are developed through in-house R & D and patented worldwide; deliver increased productivity and energy efficiency to facilities such as Thermal Power Plants, Oil Refineries, Petro Chemical Complexes, Iron & Steel industries, Cement plants, Fertiliser plants, Pharmaceutical Industries, Shopping Malls, Hotels, and Institutions.

CQM systems are highly acclaimed and well accepted in over 22 countries with more than 10000 units in the field spread over America, Europe, and Asia. All the CQM systems and services are fully compliant with CE Directives, ISO 9001: 2000 and have Green Label Certification Standards. The technology provider is also a member of NAESCO, the US National Association for Energy Services Companies (ESCO).

CQM systems save energy,eliminate costly downtime, extend capital equipment life cycle, and optimize heat transfer performance. CQM fits into the “Make in India” programme of the Government of India with its office and works in Pune, India.


Comments and feedback welcome: Knowledge Exchange Platform SecretariatBureau of Energy Efficiency, Sewa Bhawan, R.K.Puram, Sector-1New Delhi-110066 | E-mail: [email protected] more information, please visit us at: www.knowledgeplatform.in

Disclaimer: None of the parties involved in the development and production of this Newsletter assume any responsibility, makes any warranty, or assume any legal liability for the accuracy, completeness, or usefulness of any information contained in this Newsletter. This Newsletter and the information contained therein, cannot be reproduced in part or full without the written permission of the KEP Secretariat.

Knowledge Exchange Platform Update

Knowledge Exchange Platform (KEP) was launched by BEE on 26th February, 2015 in partnership with Institute for Industrial Productivity (IIP). We have been very firm on our commitment in supporting the roadmap of activities provided in the Action Plan that was released by Shri P. K. Sinha, Secretary, Ministry of Power, Government of India, at the launch event of KEP. As we are entering in 2nd year of KEP, we will be working with both PAT 1st cycle partners as well as new DCs that have joined PAT in the 2nd phase.

As you would be aware, KEP has been designed to promote and share energy efficiency best practices and technologies within and across the industry sectors covered under PAT. To enhance the effectiveness of this objective, we organized sector specific best practice workshops for Fertilizer and Iron & Steel sector with the cooperation of Indo Gulf Fertilisers on 16th February, 2016 and Godawari Power & Ispat Limited on 4th March, 2016, respectively. Alongside to the Fertilizer workshop, a visit to the Indo Gulf Fertilisers plant was also organized and the participants were taken around the control room of urea plant, ammonia plant, captive power plant and other plant areas. The Iron & Steel workshop had participation from over more than 160 distinguished speakers, eminent iron & steel industry leaders, SIMA, CREDA, certified energy managers and auditors, and energy efficient technology providers. Both workshops were successful as they were able to secure diverse stakeholder participation, active exchange of best practices and above all, was able to motivate the participating industries to explore the innovative tools of continuous improvement and embed them in their respective organizations.

We also organized Sector Learning Group (SLGs) meetings for Fertilizer and Iron & Steel Sector in order to map innovative, new and cutting edge technologies and assess the need of technological advancement in order achieve the targets set under the 2nd cycle of PAT.

KEP was also instrumental in bringing together the Aluminium and Cement industry along with the policy makers (BEE), Regulators (CPCB) and technology suppliers to promote the use of Spent Pot Liners (SPL), a by-product

generated in the Aluminium sector, as a fuel in cement industry. A Roundtable with all relevant stakeholders was organized in September, 2015 as a result of which a Joint Task Force was created under KEP to take the recommendations of the policy roundtable forward. To ensure a holistic approach and to address the relevant issues, the Task Force has been structured to ensure representation from both industry sectors viz. Aluminium and Cement; get the perspective of Regulators, viz. Central Pollution Control Board (CPCB); and also to get the feedback of technology suppliers/ developers.

The Task force currently has 17 members representing CPCB, SPCB, BEE, Aluminium, Cement, research organisations and tech. developers. The first Meeting of the Taskforce was organised on 8th January, 2015 at India Habitat Centre, New Delhi. The Task Force will help in development of an action plan to address the pressing technical, policy and coordination issues hindering the gainful utilisation of SPL with clear delineation of responsibilities to catalyze action on the ground. The Meeting helped in understanding the current status of utilization of SPL, reviewed the results of pilot initiatives carried out by some Aluminium/ Cement industry on use of SPL for co-processing, R&D status, and assessed the technical options for enhancing SPL co-processing. The Task Force also created a small working group to work with the State Pollution Control Board (SPCB) of Chhattisgarh and Odisha and work out possible solutions to deal with the regulatory barriers. IIP had also created a ‘Forum of Regulators’ under its AFR initiative with representation from the Member Secretaries of Various state pollution Control Boards and CPCB. The efforts of the Forum of Regulators and the Joint Task Force members led to amendment in the Hazardous Waste (Management, Handling and Transboundary Movement) Rules, 2008 a for including Co-processing in Cement Kiln as one of the disposal options, and Emissions Standards Emission standards for Co processing of Alternate Fuel and Raw (AFR) material in cement kiln including Hazardous Wastes, along with emission monitoring methodology and availability of facilities in India, which was notified by Ministry of Environment and Forests in March, 2016. This

will help in promoting SPL Co-processing in Cement industry.

In our effort to promote peer to peer learning, we had launched a KEP website (www.knowledgeplatform.in), which pulls together the most important resources to assist the industries improve their energy efficiency and to evaluate, select and establish a structured approach to implement the best operating and cost saving measures. The website became officially operational in December, 2015 and within a short span of time, it attracts about 350 page views every day, which is further motivating us to make it more responsive to the needs of the industry.

To keep pace with the developments and scale up the dissemination of energy efficiency practices, we have introduced various databases on KEP Website viz. Database for Energy Auditors and Energy Managers (http://knowledgeplatform.in/em-ea/)- covering the previous year examination papers, manuals and knowledge on latest advancements in energy efficient technologies, Industrial Efficiency Policy Database (http://knowledgeplatform.in/industrial-efficiency-policy-database/) - which encompasses all the Gazette notifications, EC PAT Norms, recent policy directives for PAT Cycle 2, latest updates on ESCerts Trading Mechanisms and announcements, National Energy Conservation Award Database (http://knowledgeplatform.in/portfolio/national-energy-conservation-awards/) - containing the success stories of the award winning industries which will assist other participating industries in identifying cost-effective measures that can reduce energy consumption and developing systematic approach towards energy efficiency improvements, Energy Management System Database (http://knowledgeplatform.in/portfolio/enms/) - which contains the detailed road map followed along with the challenges faced and benefits achieved by the industries who implemented EnMS in their respective organizations and Industrial Efficiency Best Practice Resources (http://knowledgeplatform.in/resource/) which contains best practice case studies of all 8 PAT sectors covering in-house projects with nil investments, revamping, energy efficient technology introductions and modifications, small group activities, energy efficiency projects etc.

knowledge exchange platform · 2016-12-21 · of best practices and new technologies. to compliment...

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