1

Best Energy Practices Implementation in

Seshasayee Paper

Knowledge Exchange Platform Workshop

Bureau of Energy Efficiency &

Institute of Industrial Productivity

New Delhi

26th Feb 2015

Dr T.G.Sundara Raman,SPB

2

Paper Industry- Emission Mitigation Strategies

• Improving Energy efficiency of the Process

• Energy Conservation

• Cleaner fuels Usage for energy generation

• Efficient high pressure cogeneration with increased cycle efficiency

• In house Biomass generated by the process [BLS,wood dust, bagasse pith etc.] usage

• Conversion of waste (solid, liquid /gaseous) to energy

3

Innovative Energy Efficient Initiatives

4

SPB: CPP Unit Process Flow

E2

C

BOILER

PSH SSH

ECO

E1

To

Process

To Process

& Deaerator

CT

OUT

IN

CW

0.1 ata

12

ata 5 ata

Steam

SJE/GSC FST

Spray

Deaerator

LP Steam

STG ~G

5

Power Enhancement Concept- First of its kind

• Automation Control Scheme Implemented & in

successful operation ensuring high degree of exhaust

condensing steam wetness related to increased

Power generation; alongside maintaining high degree

of condenser vacuum in 21 MW Extraction

Condensing STG of Captive Power Plant.

6

21 MW STG Exhaust Steam Dryness Fraction DCS Snap shot

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21 MW CPP-Power Enhancement Scheme–Summary

Section Parameter Impact Result Outcome

Condenser

–Cooling

Water

Circuit

CW Flow

increase

CW outlet temp.

drops increasing

LMTD & possible

lowering of exhaust

Steam temp.

Lowered CW exit

temperature;

Heat transfer

coefficient

increases due to

increased CW

velocity

Minor increase

in condenser

vacuum

Exhaust

Steam

wetness

Highly

desirable

[restricted

to < 15%]

Steam Enthalpy

differential increases

Enhanced Power

Generation through

increased cycle

efficiency

Power increase

: 0.3 to 0.4 MW

[inclusive of

above factor]

Condenser

Vacuum-

High

Advantage-

ous

Ensures higher

steam energy

exchange through

higher DP available

Power

enhancement

marginal

-

Generator PF >0.95

desirable

Generator efficiency

increases

Marginal increase in

Power generation

0.05 -0.1 MW

High

operating

load

Generator efficiency

increases

Increase in Power

generation

-

8

Total

Energy

Flow

Heat Release

ISPB : D-E-B / 900

Heat Release Computation

DRUM

PRESSURE

Heat Release is used as measured variable for master

fuel control algorithm

d /dt

Advantages of Heat Release:

• Independent of Fuel measurement system

• Totalizes fuel from all sources internally

• Monitors Change in Fuel quality

Innovative Project –High Pressure AFBC Boiler

9

Advances in Instrumentation & Control Automation

• Integrated Direct Energy Balance Automation

Concept in HP Cogen Plant (First of its kind )

• Power consumption reduction : 0.15 MW

• Boiler Steam Pressure Swings minimized ensuring

higher power output.

• Load Sharing Control Scheme with both Cogen

units

• With VFD - ID & PA Fans in place, Power savings

are doubled

10

Boiler #10- LOI redn. in flyash

P.A. pressure reduced from 1400 to 1200 mmWC

• LOI in Flyash reduced from 12% to 6%

• Combustion η increased by : 0.5 to 0.6 %

• Coal saving : 60 to 70 te/month

• GHGE reduction:900 to 1100 tCO2/yr

• Easy disposal of flyash to Cement mill

Waste to Energy Conversion

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Optimization of Operation of Coal fired

Cogeneration Battery

• For deriving maximum mileage from

the high cycle efficiency of CPP , it

had been decided to run the 3 MW

STG sparingly and limit steam

generation to the extent practicable in

the low pressure coal fired boilers.

The shortfall in power requirement had

been made up by grid power import.

• The above scheme coupled with the

high efficient operation of CPP unit,

avoidance of HP steam through

PRDS ( 105 bar) and implementation

of innovative Energy Management

schemes had resulted in significant

specific coal consumption reduction .

1.431.31

1.14

0

0.4

0.8

1.2

1.6

2

2011-12 2012-13 2013-14

Spec.C

oal C

onsn.[

t/t]

12

Innovative Low Carbon Schemes

13

E2

E1 E1

E2

BLR#10 VHP BLR#11

HP

P2 P1

21 MW

DEC

16 MW

EBP

LP LP

MP

Steam & Power Optimisation with 2 HP Cogen online

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Innovation related to LCE

Maximizing Green Power generation in Recovery Cogeneration Unit through:

• Minimal/No extraction & maximizing Exhaust

LP flow in 16 MW STG

• Maximizing steam inlet temperature through

operating the Recovery Boiler at high SOT &

effecting reduction in steam temperature loss

through highly effective advanced state of

the art insulation of MSL on-line

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Advanced Boiler Main steam

pipeline reinsulation- online ------------------------------------------------------------------------------

Replacing existing insulation with

fresh insulation mattress of higher

thk [210mm] & density [140kg/m3]-

with new cladding pin design

Steam temperature drop redn. from

10/12°C to 5/6 °C.

Radn & convecn heat loss redn.

Enthalpy gain in 16MW STG:

3kcal/kg

Addl. Power genern : 0.3 MW

GHGE Reduction : 2400 tCO2/ yr

Waste to Power

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E1[MP]steam redn:From 8TPH to <1TPH

• Power gen. increase …….…. : 0.4 MW

• Addl. power gen. through

increase in flow of E2 ........... : 0.05 MW

• Addl Green power gen……. : 0.45 MW

• REC ……………… : 300 units/month

• GHGE reduction ……..: 1800 tCO2/yr

16 MW STG : Energy Management Maximizing E2 steam with E1 minimal-

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# Increased BLS firing to over 700 TPD

# Optimization of Combustion air flow

•Increased HP Steam gen. …..………: > 90 TPH

•Increased Green power gen. …..: 10.5-11 MW

•Green steam to process ……..... : 33 to 36 TPH

•GHGE reduction increase: 20,000-25,000 tCO2/yr

•REC ………………… : Over 6000 units /month

Recovery Cogen - Green Energy Management

18 18

Green Power Generation from 16 MW STG integrated

to Recovery Boiler –since inception

6.36.9

7.98.3

9.05 9.39.8

0

2

4

6

8

10

12

2008-

09

2009-

10

2010-

11

2011-

12

2012-

13

2013-

14

Apr-

Dec

2014

Gre

en

Po

we

r [M

W]

19 19

Green Steam to Process

2930

36

25

30

35

40

Jan-Dec 12 Jan-Dec'13 Jan'14 -Dec '14

Steam to Process [tph]

Ste

am

- t

ph

20

Other Innovative Energy Management

Schemes

21

Boiler

Steam

Rate

TPH

Efficiency

(Energy

Efficient)%

Efficiency

(Standard

oper. )%

Net Power

Savings%

Daily

Power

Savings

in Units

10 85 70 47 50 5000

11 90 70 50 40 3000

Energy Efficient Pumps – Coal fired & Recovery Boilers

Innovative Project

Power Management - BFP

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Advanced Energy Conservation Scheme BFP for H.P. Steam Generator

Efficiency [%] of BFP in Operation

40

50

60

70

80

70 84 98 112 126 140

LargeBFP EFBFP

Feed Water Flow to Boiler 10 [ TPH]

BF

P E

ffic

iency [

%]

DP across EFBFP Control valves –Boiler 10

0

10

20

30

40

70 82 94 106 117

CV original CV LowDP

Feed Water Flow to Boiler 10 [ TPH]

DP

across B

FP

CV

[b

ar]

Energy Saving : 1000 units/day

23

.

ACF MB

ST

FWT

Process Hot /

Condensate Tank

Filter

Polished

Condensate

To Deaerators

PHEs Hot

Fluid

Process Condensate : 90°C to 35°C

DM Water Preheating : from 32°C

Heat Recovery : 4 MWt

CPU+ HRU - Integrated Water &

Energy Management - Boilers

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Total SEC Reduction – Last 3 Years

SE

C [

GJ/t

e p

rod

uct]

25

0.827

0.767

0.681

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

2011-12 2012-13 2013-14

PAT-Specific Energy Consumption Reduction S

pec

.En

erg

y C

on

su

mp

tio

n [

MT

OE

/t p

rod

uct]

26

2.532.73

3.11

0

0.5

1

1.5

2

2.5

3

3.5

2011-12 2012-13 2013-14

GHG Emission Reduction [GtoG] S

pec.C

O2 E

mis

sio

n [

tCO

2/t

pro

du

ct]

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Non Energy Benefits - New Concept [ACEEE]

• SPM in Stack gas : < 50 mg/Nm3

• Water conservation through CPU - PHE in CPP

• Nansulate coating in Dryer section – Scanner

• Water conservation through lowered Dryness

Fraction in 21 MW STG condensation steam

exhaust

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CSR -Social Promotion of GreenCo in SPB

• Treated RO water for Drinking purposes

• Waste Water for Irrigation -Cane

• Green Initiatives Awareness for School students –

Formation of Green Club in SPB High school

• Encouraging Engng College students to do Industrial

projects related to Green Initiatives

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Initiated & On-Going Green Initiatives

• Tree Farming – High Carbon Sequestration at Source

• Landscape –Greening

• Solar Heating system for Hot water for Canteen

• Green Initiative –Solar Lightpipe in Finishing House of

Paper Machine

• In-Plant Training related to GreenCo Initiatives

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Innovative Energy Conservation Schemes

Implemented-Summary Unit Activity SPB to Beneficiaries

Cogeneration Power

Plants

Direct Energy Balance-400 for

marginal increase in Power

generation

Metso Automation

Captive Power Plant Power increase through Exhaust

steam Dryness fraction maintenance

through control automation scheme

All Thermal &

Industrial Power

Plants

HP Cogeneration

Battery

MP to LP steam switch for

maximizing Power generation-STG

All Back pressure

Cogeneration units

HRU -CPU Heat recovery & DM water

conservation

Process Industries

Nansulate - Drying cylinder

ends & Scanner Steam reduction ; scanner made

operational

Nanotech. USA

Energy efficient BFP

integrated with CV

Station Power consumption reduction All Boiler Feed water

Pumps

Advanced thermal

insulation of Main steam

pipeline

Increased Green Power generation All STGs world over

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Clean ,Green & Strong

Continuously strives for improving the 3 Es-

• Energy Conservation

• Environment Control &

• Emission Reduction

On a Sustained and Continuous basis