Tamil Nadu Newsprint and Paper Limited
National Award for Excellence in Energy Management 2010
Company Profile v Promoted by the Govt. of Tamil Nadu during early eighties to manufacture Newsprint / fine paper using bagasse as primary raw material with a production capacity of 90,000 Tons/annum.
Capacity Growth (tpa)
400,000
230,000 245,000 180,000
90,000
1985 1996 2003 2008 2010 v With the commissioning of Paper Machine 3 by October 2010 the production capacity will be augmented to 4 Lakh Tons/annum.
2 Process v Pulpmill consists of Chemical Hardwood pulping (300tpd) of Super batch cooking followed by three stage Elemental Chlorine Free bleaching (ECF), bagasse handling of 8 lakhs tons per year, Chemical bagasse pulping of continuous cooking (400tpd) followed by three stage Elemental
Chlorine Free bleaching (ECF) and 15 tpd integrated ClO2 plant. v Black liquor generated from both the pulping lines after cooking is processed in Soda recovery plant where the cooking liquor is regenerated by firing spent liquor in Recovery Boiler. Also, during the process 3600 TPD of steam is generated. v Paper is made in two high speed paper machine using state of art technology of dilution head box, speed flow, Shoe press and calcoil for caliper control.
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Energy Conservation Projects Projects with no investment Projects During Achievement of energy savings per year basis 2009-10 Electricity Fuel Total (fuel) Total (Lakhs Imp.Coal in Mkcal) savings in kWh) (tonnes) (Rs.Lakhs)
Recovery of - 53 288 2.06 condensate from new hard wood plant and utilising in boiler hot well conserving heat and DM water.
Reducing compressed 1.95 - - 4.20 air discharge pressure from 6.8 kg/cm2 to 6.4 kg/cm2. 4 Energy Conservation Projects Projects During Achievement of energy savings per year Investment 2009-10 basis Rs. Lakhs Electricity Fuel Total Total (Lakhs Imp.Coal (fuel in savings (kWh) (tonnes) Mkcal) Rs.Lakhs Replacing of 3000 No. of 1.64 - - 4.92 1.20 40 watts conventional tube lights with energy efficient 36 watts tube lights. Replacing MP steam - 63 341 2.44 1.50 with LP steam in New Alfa Evaporator finishers Usage of mobile tanker - - - 1.78 2.00 for diesel fuel refilling of loaders/dozers/fork lifts
Replacing of existing 1.37 - - 2.95 2.00 cooling tower Fans with energy efficient fans in Cogen. Cooling tower.
Energy Conservation Projects Projects During Achievement of energy savings per year basis Investme 2009-10 nt Rs. Lakhs Electricity Fuel Total Total savings (Lakhs Imp.Coal (fuel) in Rs.Lakhs (kWh) (tonnes) Mkcal) Usage of Flash vapour - 365 1970 14.11 2.00 from air heater condensate tank in Recovery boiler for heating Boiler feed water, has resulted in re-using heat energy Conversion of V belt 10.67 - - 32.00 5.00 with energy efficiency flat belts for 7 equipments Replacing Diesel - - - 0.15 14.00 operated Fork lift by electric operated fork lift. Energy Conservation Projects Projects During Achievement of energy savings per year basis Investment 2009-10 Rs. Lakhs Electricity Fuel Total Total Lakhs Imp.Coal (fuel) in savings (kWh) (tonnes) Mkcal) Rs.Lakhs Installing of VFD for 5 4.66 - - 13.97 20 equipments in different plant areas RB-3 TA Fan, WBL feed pump, BL firing fan,Flash tank transfer pump& Boiler-5 PA fan 28003 MT of Waste - 4650 25110 181.20 14.00 Effluent generated in the plant fired in the Boiler and saved 4650 MT of Imported coal Recovery of blow heat - 6717 36272 259.98 14.50 and imparting the heat to the soft water used in CB ECF bleach plant.
Energy Conservation Projects
Projects During Achievement of energy savings per year Investment 2009-10 basis Rs. Lakhs Electricity Fuel Total Total Lakhs Imp.Coal (fuel) in savings (kWh) (tonnes) Mkcal) Rs.Lakhs Replacing old 4.83 - - 14.50 15.00 rewound motors 63 Nos. totalling of 1046 KW by energy efficient EFF1 new motors Utilisation of EOP - 1330 7182 51.42 15.00 filtrate heat in soft water through heat exchanger and thereby reducing LP steam consumption in CB ECF plant, has resulted in reducing heat energy. Energy Conservation Projects
Year Number of Major Projects Investment in Rs Savings Rs. Lakhs Lakhs 10 13054.6
( Around Rs 12400 2007-2008 Lakhs was spent 1277.2 under Mill development plan) 2008-2009 17 150 2380
2009-2010 14 106.2 585
Innovative projects Use of EOP Filtrate heat in Soft water Recovery of Heat from EOP Filtrate through Heat Exchangers and imparting heat to Soft Water used in Process. • Quantity of Soft Water passed through Heat Exchanger per hour = 200 Cu.M • Increase of Temperature in Soft Water due to passing of EOP filtrate through Heat Exchanger= 4°C • Cost Benefit & Savings : • Expected savings of LP Steam/day. due to increase in • Temperature in Soft Water (@ 1.20Tons/hr.) = 28.8 Tons/day. Investment : Rs 15 lakhs Net savings per annum (Rs 43970x 330 days) :Rs 51.4 Lakhs
10 Innovative projects
Blow heat recovery: Blow heat vapor let out from Digesters to the atmosphere is recovered, and utilized as useful heat energy for generation of hot water (soft water) in CB- ECF plant Benefit & Cost Savings : Quantity of Soft water attaining benefit by imparting heat : 266 M3/Hr Increase of Temperature in Soft water( from 30°C to 45° C): 15 ° C Quantity of LP Steam required to heat 266 M3/Hr from 30°C to 45 °C :6.4 T/Hr Therefore, Direct Savings due to LP Steam conservation : 6.4 T/Hr Net Savings of LP Steam :155 Tons/Day COST SAVINGS PER ANNUM :Rs. 260 lakhs (64 T/day * Rs. 685/T * 330 days) Investment : 15 lakhs
Future plans
New CFBC Boiler
It is proposed to install a new CFBC boiler 105 ata, 125 TPH and 40 MW TG to replace the old 44 ata, 60TPH Power boilers and TGs. Estimated investment : 137 Crores Savings envisaged per annum : 19.73 Crores The project has a CDM potential of generating 50,000 CERs per annum.
12 Carbon Trading (CDM) CDM Projects
· Wind Farm: Capacity (MW) CER generated
Phase II 3.00 } 45,584 CERs generated Phase III 3.75 } Phase IV 6.25 } Under Process Phase V 7.50 }
· Energy Efficiency Improvement in Chemical Recovery Boiler - MDP.
Old Recovery boiler generates 2.6 MT of steam per MT of BL solid. New Recovery Boiler – will generate 3.2 MT of steam per MT of BL solid.
Savings from CDM Projects
S.No Title of the project Implemented Year of Total CO2 Total Implementation red. In MT Annual Saving: RS Million 1 Registered CDM project I : Methane Extraction 2003 40000 32.64 and fuel conservation Project. 2 Registered CDM Project II: 6.75 MW Small 14000 11.424 Scale Grid 2004 Connected Wind Electricity Generation Project
3 CDM project III under validation: “Energy 2008 145000 118.32 Efficiency Improvement in Recovery boiler. 4 CDM project IV under validation: 13.75 MW – 2007 30000 24.48 Grid connected wind electricity generation project at Devarkulam by TNPL
5 CDM project V under validation: Methane 2008 27000 22.032 extraction and utilization as fuel Biogas - II Summary of Energy Consumption
Year Production Tons Specific Energy Consumption
Installed Actual Electrical Thermal Tons capacity Production Kwh / ton Steam/Ton
2006- 230000 231161 1461 6.69 2007
2007- 230000 245471 1421 6.47 2008
2008- 245000 254863 1404 7.4 2009 2009- 245000 245008 1362 7.18 2010
Specific Energy Consumption
Electrical Kwh / ton Thermal Tons Steam/Ton
9.36
1461 1421 1404 1500 1362 7.40 7.18
1300 6.69 6.47 1100 6.18
900
700
500 2006- 2007- 2008- 2009- 2007 2008 2009 2010 3.00 2006-2007 2007-2008 2008-2009 2009-2010
TNPL is the only mill which is having an integrated Chlorine –di-oxide plant which is energy intensive and consumes 6 MW (from 2008-2009). This is equivalent to 160 units per ton of paper produced. Specific Water Consumption
Water KL/ ton
120 108 110 100 90 90 80 70 61 60 50 2007- 2008- 2009- 2008 2009 2010
Energy Cell
• TNPL has an Energy Conservation Cell headed by G M ( E& I). The Executive Committee of the Energy Cell comprises of GM (Paper), DGM (P & RB), AGM (Energy), Manager (Energy), Manager (Pulp), Sr.Manager (SR) and Manager (Elec-Paper M/C).
• Suggestions from employees are invited , evaluated and rewarded based on returns.
• Implementation of the projects is the responsibility of Section Heads.
• The implementation is monitored by Technical outsourcing department
• The results are reviewed by Top management every fortnight. ISO Audit
ISO -9001 /14000 Surveillance Audit
During the surveillance audit by TUV Nord for compliance to ISO 9001/ 14000 standards, no non-conformances were identified by the external auditors as the all the systems were conforming to the standards set under ISO
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Renewable Energy Sources
Types of RES 2007-08 2008-2009 2009-2010 Energy Annual Energy Annual Energy Annual Generated savings Rs. Generated savings Rs. Generated savings Rs. (Lakh kwh) Lakhs (Lakh kwh) Lakhs (Lakh kwh) Lakhs Wind 543.09 2004 526 1937.78 644 2371.02
Types of RES 2007-08 2008-2009 2009-2010 Annual Annual Equ Fuel Equ Fuel Annual Equ Fuel savings savings savings ( savings ( savings savings ( Rs. Rs. MT) MT) Rs. Lakhs MT) Lakhs Lakhs
Bio Mass * 43095 136.13 42689 1957.2 21006 811.88
Bio - gas ( methane) * ('000 m3) 7383 233.32 6018 275.9 7461 288.36 Utilization of Waste
Type of waste Equivalent of conventional Waste fuel as a material Quantity of waste material energy of fuel used ( kwh percentage of total No used used ( MT) or ton /kl of fuel) energy (%) 2009- 2007- 2008- 2009- 2007-08 2008-09 2009-10 2007-08 2008-09 10 08 09 10 111665 100632 67357 48962 42420 21006 10.9 11.1 7.1 1 Bio mass 4650 Bio gas- 5705 5765 7383 6018 7461 1.64 1.46 2.03 2 '000m3 Black liquor 227371 346437 402067 171197 260847 302733 38.11 38.37 44.7 3 solids
* Equivalent conventional energy calculated in terms of Imported coal of 5380 kcal /kg at 79 % efficiency ( i.e 4250 kcal/kg )with a cost of Rs 3159 /MT Bio-mass refers to pith with GCV of 1500kcal/kg, and lagoon sludge with GCV of 1050 kcal/kg Bio gas calorific value is 5500kcal /1000 m3 Black Liquor GCV is 3200 Kcal /Kg
Replication of best practices...
• Installation of Low odour High efficiency Recovery Boiler
• Installation of energy efficient compressors.
• Installation of Vapor Absorption (VAM) in place of vapor compression system.
• Pulp bleaching sequence being changed from conventional chlorine bleaching to Elemental Chlorine Free bleaching.
22 Environment Protection...
• Uses 1,000,000 tonnes of bagasse per annum and avoids deforestation in 30,000 acres every year • TNPL has carried out plantation in 51,220 acres till March 2010 with a target of reaching 1 lakh acres by 2012-13 • Treated effluent water is pumped to TEWLIS consisting 396 farmers with 1500 acres. Amount spent so far Rs.9.20 crore. • Installed Ozone treatment plant to reduce the colour of effluent water first in India. • TNPL has obtained Forest Stewardship Council certification • Monitoring of land irrigated with TNPL’s treated effluent water through Tamil Nadu Agriculture University (TNAU) • Pulp bleaching sequence being changed from conventional chlorine bleaching to Elemental Chlorine Free bleaching.
• Generation of Green Power from 35.5 MW Wind Farm (660 lakh23 Units per year).
Environment Protection...
• Bio-methanation plant producing methane gas of about 20,000 M3/day from bagasse wash water. Methane gas used in Lime kiln saving around 12 KL of furnace oil per day.
• Usage of Agro Fuels & Black Liquor solids for Steam Generation avoiding usage of about 250,000 Mts of Fossil Fuel
• Specific consumption of water reduced from 108 in 2007 to 61 KL per tone of paper produced in 2009-10
• Obtained ISO 14001 certification for successful establishing and applying environmental management system for development, manufacture and supply of paper.
24 Awards
Award Instituted By Special Export Award from Ministry of Commerce CAPEXIL for eight consecutive years Government of India Permission to use “PANDA” Logo World Wide Fund for Nature in TNPL branded products - India “Green Rating” – 3 Leaves Center for Science and Recognizing the Environment Environment, New Delhi Management System Paper Mill of the year 2007-08 Indian Paper Mills Association TERI Corporate Env Award 2008 The Energy and Environ. Inst. ICWAI national award for excellence In cost management 2008 ICWAI Green Business Leader ship award 2009-10 for pulp and paper 25