V Nagarajan

Sr. Exe (Mech)

S Vigneshwar

JM (NDT)

V Madhusudan

Officer (NDT)

08.11.19

Owns and operates

❖ Two Paper Mills

Seshasayee Paper & Boards Limited – Unit Erode

Seshasayee Paper & Boards Limited – Unit Tirunelveli

❖ Sugar Mill

Ponni Sugars Limited

❖ High Energy Batteries Limited

A Battery Manufacturing Unit for Under Water

Propulsion, Aero-Space & Automotive Applications

❖ SPB Projects and Consultancy Limited

An Engineering/consulting company for Paper, Sugar and Power

❖ ESVIN advanced technologies Limited

A Technology Development Initiative Company

▪ Erode

▪ Tirunelveli

▪ Delhi

▪ Kolkata

▪ Mumbai

▪ Hyderabad

▪ Bengaluru

▪ Ernakulam

All our products are 100% Recyclable

Practicing TPM

Gold rated company for Green Practices

Product Portfolio – Writing, Printing, Posters & Speciality Boards

Cap

acit

y, t

/ an

nu

m

1960 2018

20000

165000

0

50000

100000

150000

200000

Always we can not afford to New Development Technology completely at

a time

Instead they apt for continual improvements with Small Upgradation in

plant and machineries.

Cap

acit

y, t

/ an

nu

m

20000

165000

Incremental Growth

with some

investments

2010- 20152000-2010 2018

Continuous

Improvement

Process

Innovation,

Deliberate

improvement,

Strategy Global

Manufacturing

Systems /

Industry 4.0 /

People Development

Leadership Development

2020

Sustainable Growth

With Social & Environmental

responsibilities

Tools: R-Gap, Deliberate Improvement, Bench Marking , TQM , TPM, ME

Major state of the art installations

& take over of sick units

Globally competitive

Op

era

tio

na

l E

ffic

ien

cy

Raw material up-gradation

Resource conservation

Product quality

Process improvement

Energy conservation

Environmental compliance

Research & Development for adoption

of technologies

Grab feed instead of manual feed to chippers - Manpower reduction

Drum chipper to cut large diameter logs

Chips screening - Kone screen instead of Oscillating screen to improve

production and chips quality

Grab mechanism for Wood Feeding Kone Screen for Improving Chips Quality

Chips production capacity

increased from 1100T/day to

1450T/day

Screen capacity increased

from 15T/Hr to 45T/Hr

With the screen enhancement specific energy consumption reduced from 6.6 KWh / T of chips to

5.9 KWh/T of chips

Chips packing in digesters is improved by having

Air evacuation system (for evacuating vapours in digesters)

Steam packing system (For charging of chips evenly inside

digester)

Rapid displacement of heat by way of tank form (Accumulators)

Effective way of heat recovery

This is highly energy conserving method of cooking when compared

with continuous digesters

12

Digester50%

DP - Return

50%

B C1 C2

Pre

-

Heate

r

Disp.

Tank

85°C

105°

Drum filters with vacuum system is replaced with Natural vacuum drum filters and

later with Twin roll press (For reduction of soda loss & less chemical consumption)

Better screening system (from bump rotor to step rotor)

Shell and Tube heat exchanger for black liquor / white liquor application replaced

with spiral heat exchanger to avoid scaling effect

Drum Filter Twin Roll Press

Trigger for this project

White liquor temperature could not be maintained in RDH station with the

conventional shell and tube heat exchanger.

This had necessitated to look into alternate advanced heat exchanger with state

of the art technology.

Why it is innovative

Spiral Heat Exchanger (SHE) with single flow channel and 100% pure counter

current flow heat exchange concept, produces flow path with high shear rate and

turbulence resulting in high heat transfer co-efficient and low fouling tendency.

Advantages of SHE

The continuous curving flow channel produced,

results in intense scrubbing effect that prevents

fouling of deposits formation.

The resultant overall heat exchange can be anywhere

from 30 to 50% higher than in conventional shell and

tube heat exchanger.

Eliminates leakages – Intra, external & bypassing –

Unlike S & T heat exchanger.

Compact unit –low footprint.

Parameter Present Earlier

Heat Exchanger Spiral Heat Exchanger Shell & Tube

White liquor outlet temperature 100 - 120 ⁰C 85 – 100 ⁰C

WBL supply temperature to

Chemical recovery Complex82 ⁰C 90 ⁰C

Savings calculation

Steam saving 25 TPD

Annual steam saving 9215 Tonnes

Cost saving 45.62 Lakhs

Annual GHG Emission reduction 2646 tCO2e

Replication Potential - Can be replicated by all industries.

Recovery Boiler producing 65 KSC pressure and 460 ºC SH steam production satisfies 50% energy

need of the Mill

S. No. Cause Actions taken Results

A Low vacuum in

surface condenser

Surface condenser water box leakage

arrested

Evaporation feed Rate

increased from 185 m3/hr

to 190 m3/hr

Post condenser changed over from PHE

to S&T condenser

Evaporation feed rate

increase from 190 m3/hr to

200 m3/hr

Orifice size for all NCG were modified Evaporation feed rate

increase to 203 m3/hr

Foul condensate vapor recirculation

improved by introducing POT.

Evaporation feed rate

increase to 210 m3/hr

BCooling water flow

problemFan less mist cooling introduced.

For sustainability and

spare O &M provided.

720730

768 775

806

640

680

720

760

800

840

BeforeReengineering

Surfacecondenser

bottom passpartition plate

leakage arresting

Post condenserchangeover from

PHE to SHE

Orifice sizechangeover

Foul condensatepot vapour

recirculation

1 2 3 4 5

HBL generated per day in TDS/D

PROS - Maintenance free - energy efficient system

Due to high TDS & TSS cooling tower water quality cooling tower spray nozzles

choked frequently resulting in 20% reduction in capacity of cooling tower leads to

poor vacuum and hindering pulp production .

So the alternate technology for replacing current cooling tower system to handle high

TDS water with less blow down the mist cooling technology was chosen.

The advantages of mist cooling includes, Fan less cooling resulting in power saving

and Approach (Water outlet temp – Wet bulb temperature) of 3 deg C achieved by the

project.

Operation friendly, Choking of water nozzle can be cleared while operating itself, can

take high COC and TDS cooling water.

Problem

• Settling rate is very high in dissolver tank and need recovery boiler stoppage

once in 3 months for cleaning.

Root cause

• Agitation is poor

Solution:

• Propose to increase the impeller diameter from 600 mm to 860 mm to

have a demo run with liquid with the beside spare tank for the sustained

run ability covering all aspects.

• On confirmation dissolver agitator was modified accordingly.

Benefits:

• Agitation improved (Verified after three months of running)

• Huge saving in investment cost

• Uniform concentration of green liquor

Before

shut

(GPL)

Top

sample

Bottom

sample

102.3 125.2

100.4 122.1

105.4 133.3

115.9 108.5

After

shut

(GPL)

105.4 102.3

111.6 114.1

116.6 120.9

115.9 119.7

The gpl variation of 15 to 30 has now reduced to 5 to 7

gpl.

Benchmarking

Gap Analysis

Action Plan

National &

Global best

Green Factory Initiatives

Practising 3R

Enhancing Energy Efficiency

Reducing GHG emissions

Continuous Improvement

Where We

Are

Skills Needed to

Get Where We’re goingWhere we

Need to Be

Power Reduction

11.14 Lakh kWh

Steam Reduction

24938 Tons

Coal Reduction

875 Tons

GHG reduction 1211.7 tCO2e

Furnace Oil Reduction

338 KL

GHG reduction 1043.9 tCO2e

Total

Savings

Rs. 47.45

Million

Total GHG

Reduction

2255.6

tCO2e

INNOVATIVE PROJECTS

Changes call for innovation, and innovation leads to progress

Trigger for the Project

To assess the organic load for effective treatment, the environmental cell

analyzed the various parameters to minimize the load to ETP at source.

Based on the study it is found that the pith filtrate from Bagasse pulp mill and

foul condensate from SRP tops the list.

Stream m3 / day PPM TPD

Foul Condensate 360 16000 5.4

Bagasse Filtrate 340 5620 2.2

Total 700 - 7.6

23%

9%68%

Evaporator Vacuum Pump sealing waterFoul Condensate Rest of the Mill Effluents

% of COD Contribution Mill Wide

Foul Condensate A Source of Energy

Foul Condensate generated from Evaporators contain reduced Sulphur gas,

Methanol, Turpentine etc

Foul Condensate Generation 8000 Kg / Hour

Methanol 7.5 Kg / Tonne of Pulp

Turpentine 0.50 Kg / Tonne of Pulp

TRS 1.20 Kg / Tonne of Pulp

Negative impact to the Environment is Odour

Untreated Foul Condensate is let out to the sewer creating huge impact to the

Environment by means of high BOD

Uniqueness – Treatment

in Anaerobic Lagoon

Scheme Details

An anaerobic lagoon was installed early in 1984 to treat the High BOD effluent

from Bagasse plant.

The biogas generated was let to the atmosphere without any collection device.

In 2013, a suitable supplier was identified to make a balloon cover above the

anaerobic lagoon to collect the bio gas and was pumped by a blower to the

Lime Kiln to a tune of 2000 Nm3/day.

Kiln Fuel reduction analysis – Day wise Energy consumption monitoring

148

147 146

150

148

149

149

151

149

146

136 137137

138

136

138 135

133

133

133

132

2572

3120

1733

2244

2712

4061

5310

43395499

6211

42664339

5341

3927

6217

7184

0

1000

2000

3000

4000

5000

6000

7000

8000

120

125

130

135

140

145

150

155

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Oil per Ton of Lime Kg Methane Gas flow

Outcome achieved by Project Implementation

Replication Potential – Can be replicated by all Integrated Pulp & Paper Mill

Description UOM QTY

Furnace oil reduction KL / day 3 – 3.5

Savings Rs in Crores / Annum 3.6

GHG Emission avoidance tCO2e 42439

COD load to ETP reduction % 20

Elimination of odor nuisance

Reduced energy and nutrient consumption in the aeration system

230000

240000

250000

260000

270000

280000

2016-17 2017-18 2018-19

271018

251238

275327

To

ns

Black Liquor generation

The predominant form of Biomass energy available at pulp mills is

Black liquor, the lignin rich by-product of fiber extraction from wood.

Our Sun,The bright alternative

Recognizing the importance of Solar Energy, SPB is exploiting the Solar Energy in

following ways:

Renewable Energy Sources Related Projects - 2020-21

Through Mill Development Plan, we are stepping up Pulp Production, thereby increasing

BLS generation 128 TPD of dry solids

Green Power generation 48,000 units / Day

Green Steam generation 350 Tons / Day

Project Office Admin Block Solar PV

Canteen Solar Heater Petrol Bunk

Proactive Maintenance

Predictive Maintenance

Preventive Maintenance

Breakdown Maintenance

MAINTENANCE REGIMES

UNPLANNED

(BREAKDOWN)

PLANNED

MAINTENANCE

AUTONOMOUS

MAINTENANCE

SPECIALISED

MAINTENANCE

PERIODIC

CHECKUP

(PREVENTIVE

MAINTENANCE)

OPPORTUNITY

MAINTENANCE

CONDITION

BASED

MAINTENANCE

PROACTIVE

MAINTENANCE

(PERIODIC

DIAGNOSIS

RCA WITH QC

TOOLS)

-VE

RESULTS

+VE

RESULTS

Predictive maintenance technique includes,

Vibration Monitoring

Thermography inspection

UT Leak Detector

Thickness Tester

Laser Alignement

Flaw Detector

Insitu-Balancing

CLO2 Vacuum Study using UT Leak Detector:

Problem

•Vacuum is drastically varying from 120 to 250 mmhg.

•In CLO2 plant generator vaccum-120 mmhg need to be maintained for boiling of

Chlorinedioxide.

Root Cause:

•System leak need to be check.

•Any Valve Passing need to be check.

Action Plan:.

•All Vacuum lines are checked for leakages.

•All Valves connected to Generator were checked for any air infiltration to the system.

Solution:

•Observed 2” ON/OFF valve passing

and it is connected to generator as

shown in the figure.

•After changing the valve immediately

and vacuum maintained at 120 mmhg.

Advantage UT Leak Detector:

By running itself system problem will

be identifed.No Stoopage required.

By this way following defects can be

identified using UT Leak Detector:

•Steam Trap Passing.

•Air leak.

•Diagnosis of Slow speed bearings

Pickup roll with drives removed and scrapper system introduced in BSW washer 2 with all clamping

arrangements.

• Productivity improved by about

140 tons per month

• Nil Down time from the earlier 7

hrs/month

• Inventory in procuring pickup

roll bearings eliminated

• Safety and good house keeping

Lime Kiln Shell Temperature Study using Thermography:

Shell temperature Study through Thermography advancement:•In SRP Lime kiln Area shell temperature was checked periodically.•Shell temperature checked from Feed End to Discharge End.Problem:On periodic checking shell temperature was raised to 515*C at satellite cooler area.

Action Plan:

•Lime kiln stopped and checked for any brick failure.

•Found some bricks missing in the shell area.

•Then Bricks lined to the shell area.After Rectification:•Shell temperature reduced from 515*C to 362 *C

After bricks changing

Focussed on prioritisation of Safety / Quality in production and

environment, Healthiness with respect to performance

Organisation has a strong belief, more the number of Kaizens, more

employee involvements in its functional objective.

Functional managers to promote Kaizens.

To optimise the equipments in service to run in its ideal condition by

continuous monitoring

To take care of employee welfare on different grounds by CREP activities,

Housing, Schooling at affordable cost and other social activities in and

around mill premises.

The Future Is Ours to Create

Command to consensus

Control to Commitment

Compliance to Creativity