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.

3

Energy Conservation Projects Projects with no investment Projects During 2009-10

Achievement of energy savings per year basis Electricity (Lakhs kWh)

Fuel Imp.Coal (tonnes)

Total (fuel) in Mkcal)

Total savings in (Rs.Lakhs)

Recovery of condensate from new hard wood plant and utilising in boiler hot well conserving heat and DM water.

-

53

288

2.06

Reducing compressed air discharge pressure from 6.8 kg/cm2 to 6.4 kg/cm2.

1.95

-

-

4.20

4

Energy Conservation Projects Projects During 2009-10

Achievement of energy savings per year basis

Investment Rs. Lakhs

Electricity (Lakhs (kWh)

Fuel Imp.Coal (tonnes)

Total (fuel in Mkcal)

Total savings Rs.Lakhs

1.64

-

-

4.92

1.20

Replacing MP steam with LP steam in New Alfa Evaporator finishers

-

63

341

2.44

1.50

Usage of mobile tanker for diesel fuel refilling of loaders/dozers/fork lifts

-

-

-

1.78

2.00

Replacing of existing cooling tower Fans with energy efficient fans in Cogen. Cooling tower.

1.37

-

-

2.95

2.00

Replacing of 3000 No. of 40 watts conventional tube lights with energy efficient 36 watts tube lights.

Energy Conservation Projects Projects During 2009-10

Achievement of energy savings per year basis

Investme nt Rs. Lakhs

Electricity (Lakhs (kWh)

Fuel Imp.Coal (tonnes)

Total (fuel) in Mkcal)

Total savings Rs.Lakhs

Usage of Flash vapour from air heater condensate tank in Recovery boiler for heating Boiler feed water, has resulted in re-using heat energy

-

365

1970

14.11

2.00

Conversion of V belt with energy efficiency flat belts for 7 equipments

10.67

-

-

32.00

5.00

Replacing Diesel operated Fork lift by electric operated fork lift.

-

-

-

0.15

14.00

Energy Conservation Projects Projects During 2009-10

Achievement of energy savings per year basis

Investment Rs. Lakhs

Electricity Lakhs (kWh)

Fuel Imp.Coal (tonnes)

Total (fuel) in Mkcal)

Total savings Rs.Lakhs

Installing of VFD for 5 equipments in different plant areas RB-3 TA Fan, WBL feed pump, BL firing fan,Flash tank transfer pump& Boiler-5 PA fan

4.66

-

-

13.97

20

28003 MT of Waste Effluent generated in the plant fired in the Boiler and saved 4650 MT of Imported coal

-

4650

25110

181.20

14.00

Recovery of blow heat and imparting the heat to the soft water used in CB ECF bleach plant.

-

6717

36272

259.98

14.50

Energy Conservation Projects Projects During 2009-10

Achievement of energy savings per year basis

Investment Rs. Lakhs

Electricity Lakhs (kWh)

Fuel Imp.Coal (tonnes)

Total (fuel) in Mkcal)

Total savings Rs.Lakhs

Replacing old rewound motors 63 Nos. totalling of 1046 KW by energy efficient EFF1 new motors

4.83

-

-

14.50

15.00

Utilisation of EOP filtrate heat in soft water through heat exchanger and thereby reducing LP steam consumption in CB ECF plant, has resulted in reducing heat energy.

-

1330

7182

51.42

15.00

Energy Conservation Projects Year

Number of Major Projects

Investment in Rs Lakhs

10

13054.6

Savings Rs. Lakhs

( Around Rs 12400 Lakhs was spent under Mill development plan)

2007-2008

1277.2

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.) Tons/day. Investment

=

28.8

: 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 CBECF 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: Phase II Phase III Phase IV Phase V

•

Capacity (MW) 3.00 3.75 6.25 7.50

} } } }

CER generated 45,584 CERs generated Under Process

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

1

Registered CDM project I : Methane Extraction and fuel conservation Project.

2

Registered CDM Project II: 6.75 MW Small Scale Grid Connected Wind Electricity Generation Project

Year of Implementation

2003

Total CO2 red. In MT

Total Annual Saving: RS Million

40000

32.64

14000

11.424

2004

3

CDM project III under validation: “Energy Efficiency Improvement in Recovery boiler.

2008

145000

118.32

4

CDM project IV under validation: 13.75 MW – Grid connected wind electricity generation project at Devarkulam by TNPL

2007

30000

24.48

5

CDM project V under validation: Methane extraction and utilization as fuel Biogas - II

2008

27000

22.032

Summary of Energy Consumption Year

Production Tons

Specific Energy Consumption

Installed capacity

Actual Production

Electrical Kwh / ton

Thermal Tons Steam/Ton

20062007

230000

231161

1461

6.69

20072008

230000

245471

1421

6.47

20082009

245000

254863

1404

7.4

20092010

245000

245008

1362

7.18

Specific Energy Consumption Thermal Tons Steam/Ton

Electrical Kwh / ton 9.36

1461

1500

1421

1404

1362

7.40 7.18

1300

6.69 6.47

1100

6.18

900 700 500 20062007

20072008

20082009

20092010

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

120 110 100 90 80 70 60 50

108 90

61

20072008

20082009

20092010

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

19

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 Types of RES

543.09

2004 2007-08

526

1937.78 2008-2009

644

2371.02

2009-2010

Equ Fuel savings ( MT)

Annual savings Rs. Lakhs

Equ Fuel savings ( MT)

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

Annual Equ Fuel savings savings ( Rs. Lakhs MT)

Annual savings Rs. Lakhs

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 (%) 2007-08 100632

1

Bio mass

2

Bio gas'000m3

5705

227371

3

Black liquor solids

2008-09 2009-10 111665 67357 4650

5765

346437 402067

2007-08

2008-09

200910

200708

200809

200910

48962

42420

21006

10.9

11.1

7.1

7383

6018

7461

1.64

1.46

2.03

260847 302733 38.11

38.37

44.7

171197

* 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 lakh 23 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 in TNPL branded products

World Wide Fund for Nature - India

“Green Rating” – 3 Leaves Recognizing the Environment Management System

Center for Science and Environment, New Delhi

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