Post on 29-May-2018
CII National Award for
“Excellence in Energy Management - 2017”
ITC Limited, PSPD, Unit - Kovai
ITC Ltd. , PSPD , Unit: Kovai is located 42 km North of Coimbatore, Tamil Nadu
Acquired from BIPCO in March 2004
Manufacture Duplex Board from 100 % recycled fiber
Production capacity of 1,20,000 Tons / year
Employment to 1000+ people
Certifications:
ISO 9001 : 2015; ISO 14001 : 2015; OSHAS 18001 : 2007
Certified for Forest Stewardship Council (FSC)
First Indian Manufacturing unit to gain WWF’s Global Forest Trade NetworkMembership
ITC PSPD Unit Kovai – First Company in the Pulp and Paper Sector to receiveGreenCo Platinum rating
Under GREEN POLICY, ITC Kovai is committed to monitor and improve our efforts fora cleaner environment and a better future for everyone
CII Excellent Energy Efficient Unit 2010, ’14, ‘15
Mill Introduction
Process Flow
TL wire
Coater Dryers,
MG, Calender
Board machine
ETPTreated Effluent
for Irrigation
Petax Filter
Cogen 8MW
Steam
Water from River
Condensate
FuelEmission:
SPM <30ppm
Sp. Water: 9.8 m3/T
Reel & Rewinder
She
eter
s
Finishing House
Despatch
Stock Preparation
PulperWaste Paper
ScreenCentri cleanerHot disperser
FL wirePulperWaste Paper
ScreenCentricleanerHot disperser
BL wirePulperWaste Paper
ScreenCentricleanerHot disperser
Water Treatment
DM Plant
Press&
TemsecRewinder
Sp. Power: 588 Units/T
Treated Effluent Reuse
TSS <30ppm
Windmill 7.5MW
Sp. Discharge = 5.5 m3/ MT
TG8 MW
Board M/C Q = 21TPH
Stock prep Q = 2.5TPH
VAM Q =0.3TPH
Thermo compressor Q=2.4TPH
Air tunnels Q=3.2TPH
HP SteamQ=43.4 TPH
LP Ext Q=29.8 TPH
MP Bleed Q=5.6 TPH
Stock Preparation – 222 kWh/ ton
Board Machine & CCK – 229 kWh/ton
Utilities –91.4 kWh/ ton
Finishing house – 10.3 kWh/ ton
HVAC & Lighting – 7.1 kWh / ton
Intake pump house– 5.2 kWh /ton
Mill Overall Energy Balance
Deaerator Q = 6TPH
To condenser Q = 8TPH
Windmill 7.5MW
5 MW 2.5 MW
600
588 586
565
550
560
570
580
590
600
610
2013-14 2014-15 2015-16 2016-17
Specific Power (kWh/MT of FNP)
5.8% Reduction
2.51
2.39 2.39
2.32
2.20
2.25
2.30
2.35
2.40
2.45
2.50
2.55
2013-14 2014-15 2015-16 2016-17
Specific Steam (MT/MT of FNP)
7.6% Reduction
Cycle 1 - PAT Performance (MTOE/T)
0.34800.3410
0.2900
0.2600
0.2700
0.2800
0.2900
0.3000
0.3100
0.3200
0.3300
0.3400
0.3500
0.3600
Baseline Target 2014-15
Unit Kovai Power Source (%)
Comparison Bio-fuels in 2016-17
59% 27%
CO4
DOB
Saw Dust
Charcoal Powder
Saw Dust
Bio-fuels in 2013-14
13 2039 42
2331
59 5437
27
0 0
0%
20%
40%
60%
80%
100%
2013-14 2014-15 2015-16 2016-17
Cogen Biomass Windmill Cogen fossil State EB
73% Power Source was Renewable in 2016-17
Summary of Energy Savings & Investment
YearSum of Annual Energy
savings (Lakh Units)
Sum of Total Annual Savings
(Rs Lakhs)
Sum of Invest. Made
(Rs Lakhs)
Payback(Months)
2016-17 17.9 84.2 76.8 11
2015-16 9.82 49.1 65.2 16
2014-15 15.35 53.74 66.25 15
Total 43.07 187.04 208.25 13
YearSum of Annual Steam
savings (Tonnes)
Sum of Total Annual Savings
(Rs Lakhs)
Sum of Invest. Made
(Rs Lakhs)
Payback(Months)
2016-17 503 15 44.5 36
2015-16 1275 38.27 148 46
2014-15 2140 21.4 34 19
Total 3915 74.67 226.5 36
Steam
Power
Innovative Project – 1 (Internal EnCon idea)Replacement of traditional Starch Agitators with Efficient One
Past Scenario :
Coating Kitchen Starch Preparation Agitators were installed in 1995 & it was operating with 30KW motor.
It was not looked as Energy Saving Potential Equipment for last so many years.
Present Scenario:
Through technology advancement, we were able to identify a suitable agitator which can reduce power consumption by 97%.
Energy savings 425 Units/Day
Investment 3.5 Lakhs
Payback 6 Months
EquipBefore
KWAfterKW
Starch Tank 2 Agitator 30 0.75
Modified Design
97%
Reduction
Innovative Project – 2 (Internal EnCon idea)Replacement of 52 Nos MH Lamp with 18Nos Plasma
Past Scenario :In our Finishing House & Godown, we were
using 52Nos of 250W Metal halide Lamps for internal lighting. MH lamps are in efficient & it also requires lot of Maintenance. One team use to work continuously for lighting maintenance.
Present Scenario:LEP (Light Emitting Plasma) lamps were
installed in Himast and technology was explored for Hibay lamps. We were able to reduce 52Nos of MH light fittings with 18Nos 260W Plasma lamps.
• Energy Savings 70%• Its maintenance free also.
Project Summary:
Energy Savings 131 Units/Day
Investment 11.7 Lakhs
Payback 5.4 Years
CO2 Emission Reduction
• Plant Details - 8MW Cogeneration with 60TPH steam generator.
• Fuel used: Predominately Biomass Co-fired with fossil fuel.
– Biomass : De-oiled Rice Bran, Saw Dust, Wood Chips, Charcoal dust
– Fossil Fuel: Coal, Lignite
– Biomass consumption: 75K MT (2016-17)
Utilization of Agro Residue Biomass in Co-Generation System:
• Plant Details – 1.5MW X 5 Nos = 7.5MW Windmill
• 200 Lac Units Generation Potential / Annum
Utilization of renewable Windmill Power for Production
Energy Efficient Agitators & Aerator
Title of Energy Saving project implementedYear of
Implementation
Annual Energy savings (LakhUnits)
Total Annual Savings
Invest. Made Payback
months
Rs Lakhs Rs Lakhs
Energy Saving Agitator for FL Blend Chest2016-17
0.63 2.9488.12 33
Energy Saving Agitator for FL HD TOWER2016-17
0.59 2.7528.12 35
Energy Efficient Aerators for ETP2016-17
6.93 32.43225.8 10
Total 8.15 38.13 42.04 13
Energy Efficient Lighting & MotorReplacement of 150 Office Lights with 36W LED 2016-17 0.32 1.52 3.9 31
Energy Efficient IE3 Motor for Mini Press 2016-17 0.02 0.12 0.16 17
Total 0.34 1.64 4.06 29
Energy Efficient Pumps (Part 1)
Title of Energy Saving project implementedYear of
Implementation
Annual Energy savings (LakhUnits)
Total Annual Savings
Invest. Made Payback
months
Rs Lakhs Rs Lakhs
Energy Efficient Makeup water pump 2016-17 0.34 1.589 1.117 8
Energy Efficient Recovery fibre chest pump 2016-17 0.27 1.278 1.12 11
Energy Efficient Vac Cooling Tower pump 2016-17 0.12 0.550 1.75 38
Energy Efficient Process Cooling water Pump 2016-17 0.77 3.589 1.72 6
Energy Efficient Vacuum hot well pump 2016-17 0.17 0.814 3.92 58
Energy Efficient Krofta Feed Pump 2016-17 1.36 6.369 1.98 4
Energy Efficient New SS Tank Feed Pump 2016-17 1.25 5.846 1.8 4
Energy Efficient Pumps (Cont)
Title of Energy Saving project implementedYear of
Implementation
Annual Energy savings (LakhUnits)
Total Annual Savings
Invest. Made Payback
months
Rs Lakhs Rs Lakhs
Energy Efficient Recovered Fiber pump 2016-17 0.21 0.995 1.12 14
Energy Efficient Krofta High Pr Pump 2016-17 1.59 7.442 0.84 1
Energy Efficient CPU Feed Pump UTY 2016-17 0.05 0.244 0.45 22
Energy Efficient UF Feed Pump_Uty 2016-17 0.09 0.427 0.58 16
Energy Efficient RO transfer pump 2016-17 0.09 0.417 1.29 37
Total 6.32 29.56 17.69 7
VFD Applications
Title of Energy Saving project implementedYear of
Implementation
Annual Energy savings (LakhUnits)
Total Annual Savings
Invest. Made Payback
months
Rs Lakhs Rs Lakhs
VFD for Chest no 12 & 13 2016-17 0.70 3.3 1.8 7
VFD for Chest no17 2016-17 0.74 3.5 1.8 6
VFD for Top HD ring dilution pump 2016-17 0.62 2.9 1.8 7
VFD for HD tower pump top 2016-17 0.24 1.1 1.8 19
VFD for Filler blend chest pp Chest 22 2016-17 0.47 2.2 1.8 10
VFD for New TCC feed pump 2016-17 0.20 1.0 1.8 23
VFD for DM2 agitator 2016-17 0.22 1.0 0.82 9
Total 3.19 14.92 11.62 9
List of Major ENCON efforts planned for the next 3 years
S No 8Energy Conservation Action PlanElectrical
(Units/Annum)
Thermal Savings
(Ton of Coal/ Annum)
Lakh Savings / Annum
1 Recovering Bio gas from MLSS & canteen waste 54750 350 47
2 Efficient Vacuum Pumps 525000 25
3 Energy conservation Schemes 297500 14.8
4 Fuel Shed 500 15
5Replacement of inefficient traditional agitators with energy efficient agitators for pulp storage chest
350000 16.2
6Replacement of old pumps with new higher efficiency pumps at identified locations
262500 12.1
7Installation of Variable Frequency Drives for various equipments
400000 18.5
8 Steam system optimisation 500 15
18
250
150131
89 86104 108
0
50
100
150
200
250
300
TNPCB Norm
CPCB Norm
revised
2012-13 2013-14 2014-15 2015-16 2016-17
COD2100
1600
1145 1073 1112 1164 1085
0
500
1000
1500
2000
2500
TNPCB Norm
CPCB Norm
revised
2012-132013-142014-152015-162016-17
TDS
100
3040.2 39
31.9 27.9 25.6
0
20
40
60
80
100
120
TNPCB Norm
CPCB Norm
revised
2012-132013-142014-152015-162016-17
TSS30
20
7.7 7.6 6 5.5 5.6
0
5
10
15
20
25
30
35
TNPCB Norm
CPCB Norm
revised
2012-13 2013-14 2014-15 2015-16 2016-17
BOD
Waste Management – ETP Water
Utilization of Waste Material
ETP Sludge
• 100% sludge generated is reused in process
Process Plastics Waste
• 100% sent to cement plants to Co-process in kiln
Fly Ash
• 100% fly ash generated sent to recycled for fly ash brick making
Energy Conservation Projects Generation
• TPM (Lean Manufacturing)
- Kaizen
- Focused Improvement Projects
• Energy cell
- Internal Audits (By Energy cell members)
- External Audits (By Third Party)
- Campaigns
ENERGY MANAGEMENT CELL KPOV’s 17-181) Targets
• Power Reduction: 61 units/ Tonne of FNP
• Steam Reduction: 0.36 Tonne/ Tonne of FNP
2) Energy Audits planned for 2017-18: Vacuum system Audit
3) Identification of one Encon Project per month and co-ordination for implementation.
4) Knowledge sharing on energy conservation – Minimum two per month
S No Name Specialist Area of focus
1 R Muralidaran Energy Manager Overall
2 P Premaguru Utility AET- Process Specialist Water
3 D Ranjith Kumar Stock Preparation AET- Engg Specialist Power
4 V Abinesh Stock Preparation AET- Eng Specialist Power & Steam
5 TK Jegadish Board Machine AET- Process Specialist Power & Steam
6 Jasper Devapaul Board Machine AET- Engg Specialist Power & Steam
7 N Vijayakumar Finishing House AET - Engg Specialist Air
8 M Phaneendhra Utility AET- Engg Specialist Power
Energy Cell Members & Role
Energy Cell Celebrations
• Energy Conservation Day
• World Water Day
• World Environmental Day
• Ozone Day
S No Title of ProjectYear of
implementation
Name of Associate/Vendor
Energy Unit
Energy consumptio
n before project
Energy consumpti
on after project
% Improve
ment
1Encouraging & Coordinating vendors for GreenCo certification
2016-17 Fimakem NA NA NA na
2Increase in productivity of the Sheet cutter
2014-15Suriya Cutting
WorkskWh/
MT4 3 17.95%
3Reduction of Environmental Impact
2014-15 FimachemkWh/ Day
11002 9793 10.99%
4To Replace old motors with new IE2 motors.
2013-14
M/s.ManoramaPradhan Paper and Board – Karamadai
kWh 45 34 24.44%
5Replacement of Old Earth moving vehicle with energy efficient vehicle
2013-14Coimbatore Earth
Movers
Liters of Diesel/
Day128 96 25.00%
EnCon Projects implemented by Associates/ Vendors
First Greenco – Platinum rated Paper Mill in India, 2015 CII National Award
Safety award -2012 & 2015 National Safety Council of India
Productivity Award 2013, ‘14 Coimbatore Productivity Council
Excellent in Energy Management 2014, ‘15 , ‘16 CII National Award
Best Environmental performance-Innovative Project, 2013 CII National Award
1st Position at Green Award 2013 TNPCB, Government of Tamil Nadu
2nd Position at Green Award 2014 TNPCB, Government of Tamil Nadu
EHS Excellence Award, 2013 CII National Award
5 Star Safety Rating, 2007, ’08,’10,’11 British Safety Council
5 Star Environment Rating, 2011 British Safety Council
International Safety Award, 2010 British Safety Council
Globe of Honor for Environment,2011 British Safety Council
Excellent Water Efficient Unit, 2007, ‘08, ‘09, ‘11 CII National Award
Excellent Energy Management, 2010, 14, 15 CII National Award
National Energy Conservation Award, 2010 Bureau of Energy Efficiency24
AWARDS & ACHIEVEMENTS
THANK YOU