Slide No. 1J K PAPER LIMITED…….Creating Lasting Impressions
JK PAPER LIMITED
BEST ENERGY EFFICIENCY PRACTICES AT UNIT : CPM, FORT SONGADH, GUJARAT
Presentation by: Darab Khan, GM(Project & Development)
Date : 21st Aug, 2015
Slide No. 2J K PAPER LIMITED…….Creating Lasting Impressions
JK Paper Today
An Industry benchmark with Power Packed Brands
Slide No. 3J K PAPER LIMITED…….Creating Lasting Impressions
JK PAPER LTD IS ONE OF THE LEADING COMPANIES OF JK ORGANIZATION – A PROMINENT BUSINESS HOUSE OF INDIA FOUNDED OVER 100 YEARS AGO
TyreCement
Agri Genetics
V-Belts- Oil Seals & Power Transmission Systems
Clinical Research
Hospital & Health services
USD 3.7 Billion
23 manufacturing plants
Present in 80 countries
More than 30,000 employees
Paper
Education
Dairy Products
Defence Electronics
Slide No. 4J K PAPER LIMITED…….Creating Lasting Impressions
JK’S BRANDS ARE INDUSTRY BENCHMARKS IN RESPECTIVE PRODUCT CATEGORIESPLANTS WITH STATE OF THE ART TECHNOLOGY AND MINIMAL ENVIRONMENTAL IMPACT
Panoramic view of the Unit JKPM (Orissa) -295,000 tpa)
Panoramic view of the CPM (Surat, Gujarat) – 160,000 tpa
Copier Paper (Market Leader – 26% Share)
Coated Paper ( Amongst top Two – 9% Share)
Packaging Board( Amongst top Two – 16%
Share)
Slide No. 5J K PAPER LIMITED…….Creating Lasting Impressions
STRATEGIC GEOGRAPHICAL PRESENCE
• Strategic location
– JKPM located close to raw material sources
– CPM located close to large end customers & port
• Strong distribution reach
– 4 regional offices
– 11 warehouses
– 180 distributors
– over 4,000 dealers
UNIT : CPM
Pulp (tpa) 60,500
Paper (tpa) 55,000
Pkg. Boards (tpa) 90,000
Total Production Capacity
Saleable Product : 455,000 tons per annum (tpa)Pulp : 275,500 tpa (BD)
UNIT : JKPM
Pulp (tpa) 215,000
Paper (tpa) 295,000
Combined strength of ~ 4800 employees at both the locations
Slide No. 6J K PAPER LIMITED…….Creating Lasting Impressions
VISION,MISSION & CORE VALUES
Slide No. 7J K PAPER LIMITED…….Creating Lasting Impressions
INTRODUCTION TO JK PAPER, UNIT: CPM
JK Entered in paper business in 1938.
JKPM was set up in Odisha in 1962
JK acquired CPM In 1992, and turned around it by the year 1994-95.
Paper business consolidated in 2000-01 under JK Paper Ltd.
Packaging Board Plant commissioned in 2007
Slide No. 8J K PAPER LIMITED…….Creating Lasting Impressions
JK took over the Management in July 1992
After rehabilitation full production of Pulp & Paper started in 94-95
Company’s worth became positive in June 1996 & Company came out of BIFR
purview on 17th February 1997
JK Paper Mills (Paper undertaking of JK Corp Ltd.) transferred as a going concern
to the Company from 1st April 2000
Company’s name changed to JK Paper Ltd. on 5th November 2001
Substantial expansion – Packaging Board Plant of 60,000 TPA with energy efficient
CFB and TG – 12 MW at a Capital Cost of Rs.300 Cr. Commissioned on February 17,
2007 and commercial production started from October 21, 2007.
CPM’s present Capacity of Paper & Board is 1,45,000 TPA.
POST TAKEOVER PERIOD
Slide No. 9J K PAPER LIMITED…….Creating Lasting Impressions
STRATEGIES ADOPTED TO OVERCOME THE CHALLENGES
Product development & Product up-gradation
Production capacity enhancement
Technological improvement
Organization Development interventions & effective Human Resource Management
Training & development
Innovations & continuous improvement
Implementation of TPM
Implementation of Process Based Organization (PBO).
Development of in-house strength for de-bottlenecking and Low Cost solution.
Infrastructure development
Strong team work
Focus on CSR activities
Slide No. 10J K PAPER LIMITED…….Creating Lasting Impressions
115
108
123
120
118
127
139
141
139
150 1
54 157
166
155
155
166
100
120
140
160
180
1999-0
0
2000-0
1
2001-0
2
2002-0
3
2003-0
4
2004-0
5
2005-0
6
2006-0
7
2007-0
8
2008-0
9
2009-1
0
2010-1
1
2011-1
2
2012-1
3
2013-1
4
2014-1
5
Increase in Pulp Production Capacity
127
128
140
142
138 141
143 147
147
145
152
152
148
159
150
137
100
120
140
160
180
200
1999-0
0
2000-0
1
2001-0
2
2002-0
3
2003-0
4
2004-0
5
2005-0
6
2006-0
7
2007-0
8
2008-0
9
2009-1
0
2010-1
1
2011-1
2
2012-1
3
2013-1
4
2014-1
5
157
191 207
237 249
243
243
50
10 0
150
2 0 0
2 50
3 0 0
39
4
38
0
40
8
38
5
35
9
34
3
30
2
14
7
14
7
14
3
14
1
13
8
14
0
12
8
12
7
14
2
050
100150200250300350400450
1999-0
0
2000-0
1
2001-0
2
2002-0
3
2003-0
4
2004-0
5
2005-0
6
2006-0
7
2007-0
8
2008-0
9
2009-1
0
2010-1
1
2011-1
2
2012-1
3
2013-1
4
2014-1
5
Increase in Paper Production Capacity Increase in Board Production Capacity
Increase in Paper & Board Production Capacity
JOURNEY OF OPTIMAL PERFORMANCE .
TP
D
Years
TP
D
TP
D
Trend of production Capacity Enhancement
YearsYears Years
TP
D
Low production due to
unfavourable market
condition & change in
productmix
Low production due to
unfavourable market
condition & change in
product mix
Low production due to
unfavourable market
condition & change in
productmix
Slide No. 11J K PAPER LIMITED…….Creating Lasting Impressions
Best Practices in Energy Efficiency
Slide No. 12J K PAPER LIMITED…….Creating Lasting Impressions
UTILITY CONSUMPTION PER TONE OF PRODUCT (SALABLE PULP + PAPER +
BOARD)
Particulars Unit
Before Energy
Saving Schemes
Year (2010-11)
After Energy
Saving Schemes
Year (2014-15)
Percentage (%) of
Reduction
Power
consumptionKWH/T 937 922 1.60
Steam
consumptionT/T 7.33 6.91 5.73
Water consumption m3/T 50.80 45.17 11.08
Coal consumption T/T 1.428 1.437 -0.63*
Own Power
generation% 97.82 98.88 1.08
Grid Power
consumption% 2.18 1.12 48.63
* Coal consumption increased due to use of lignite (Law quality fuel)
Slide No. 13J K PAPER LIMITED…….Creating Lasting Impressions
SEC TARGET PAT FIRST CYCLE
0.601
0.57
0.524
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
Base Year Target Assessment
Year 2014-15
Target Achieved
2014-15
MO
ET
PAT first
cycle
Unit Value
SEC of a base
year Average of
2007-08,2008-
09,2009-10
MOET 0.601
Target of SEC
(Assessment
year 2014-15)
MOET 0.57
SEC achieved
PAT
(Assessment
year 2014-15)
MOET 0.524
Trend of SEC Target PAT First Cycle
Slide No. 14J K PAPER LIMITED…….Creating Lasting Impressions
ENERGY SAVINGS SCHEMES IMPLEMENTED
13
28
14
10
9
1.8
7 3.0
5
13.7
5
4.7
6
3.4
5
5.8
33.2
2
14.8
7
10.1
8 12.3
3
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
2011-12 2012-13 2013-14 2014-15 2015-16 (Apr-
Jun'15)
No of SchemesTotal Investment Rs. MillionSavings Rs. Million
Trend of Energy Savings Schemes Implemented Year No. of
scheme
s
Total
Investme
nt
Rs.
Million
Savings
Rs. Million
2011-12 13 1.87 5.80
2012-13 28 3.05 33.22
2013-14 14 13.75 14.87
2014-15 10 4.76 10.18
2015-16
(Apr-
Jun’15
09 3.45 12.33
Slide No. 15J K PAPER LIMITED…….Creating Lasting Impressions
ENERGY SAVING SCHEMES IMPLEMENTED IN THE YEAR
2011-12,2012-13 , 2013-14, 2014-15 & 2015-16
YEAR 2011-2012 PAPER PLANT & BOARD PLANT
Year of Implementation
Annual Electrical Savings achieved
Annual Thermal Savings Total Annual Savings
Rs. Million
Invest made.Rs. Million
Payback Months
Units Million Rs. MillionTons of Coal or Oil
Rs. Million
1 Power saving due to installation of VFD in Recovery Boiler Firing Liquor Pumps
2011-12 0.078 0.260 0.260 0.400 18.462
2 Replacement of PM-I Uhle box vacuum pump motor by energy efficient pump
2011-12 0.037 0.135 0.135 0.135 12.000
3 Power saving due to trimming of impeller of TG-IV cooling tower circulation pump.
2011-12 0.453 1.950 1.950 0.005 0.031
4 Power saving by minimising lights & lighting hrs in Power Block
2011-12 0.039 0.124 0.124 0.155 15.000
5 Power saving due to bypassing one causticizer in each of the two stages in Causticizing.
2011-12 0.104 0.451 0.451 - Immdiate
6 Power saving due to bypassing Lime sludge storage tank & pump by providing VFD in LMW-III under flow pump making closed loop with lime sludge filter vat level.
2011-12 0.125 0.540 0.540 0.250 5.556
7 Operating one Cooling Tower fan of TG-IV in Controlled temperature range.
2011-12 0.085 0.273 0.273 0.050 2.198
8 Power saving due to minimising lighting hours in Recovery Boiler
2011-12 0.025 0.106 0.106 0.055 6.226
9 Power saving due to providing level switch with auto start/stop for sand cleaner reject pit pump
2011-12 0.024 0.103 0.103 0.065 7.573
10 Power saving due to replacing old Broke Pulper No.1 "DELTA" starter by "STAR DELTA" starter
2011-12 0.170 0.730 0.730 0.360 5.918
11 Power saving due to changing the Wills Cutter Trim Blower Motor from "Delta" connection to "Star" connection.
2011-12 0.051 0.218 0.218 0.020 1.101
12 Replacement of warm water by hot water in HypoWasher Screw Conveyor.
2011-12215.00
0.826 0.826 0.031 0.450
SUB TOTAL (PAPER PLANT)1.191 4.890
215.000 0.826 5.716 1.526
13 Installation of Energy saver for lighting of Board Plant Part-II
2011-12 0.020 0.087-
- 0.087 0.342 4.504
SUB TOTAL (BOARD PLANT)0.020 0.087
-- 0.087 0.342
TOTAL (PAPER +BOARD PLANT)-2011-12 1.211 4.977 215.000
0.826 5.803 1.868
Slide No. 16J K PAPER LIMITED…….Creating Lasting Impressions
YEAR 2012-2013
PAPER PLANT yearUnits
million
Rs. In million
Tons of coal
Rs.inmillion
Total savings
Totalinvestment
paybackMonth
1 Power saving due to installation of Energy Efficient Agitators in Talcum and WGCC Service Tanks 2012-13 0.376 0.375 0.3750.053 0.141
2 Power saving by reduction of PM-II Condensate pump rpm from 1500 to 900. 2012-13 0.015 0.070 0.070- Immediate
3 Power saving due to Installation of Cooling Tower for cooling the sealing water of vacuum pump in PM-I & PM-II. 2012-13 0.226 0.750 0.7500.500 0.667
4 Power saving by operating the PM-II Condensate pump at 30 Hz instead of 50 Hz. 2012-13 0.015 0.064 0.064- Immediate
5 Power saving by minimising lighting hrs in Causticizing area 2012-13 0.018 0.082 0.0820.045 0.549
6 Power saving due to stopping Blower of instrument air dryer & providing air through tapping taken from CFB-4 FD fan duct.
2012-13 0.267 0.123 0.1230.020 0.163
7 Replacement of Normal bulbs by CFL 2012-13 0.007 0.029 0.0290.038 1.310
8 Power saving due to bypassing PM-II Machine chest Agitator (Except during run of Ledger, Parchment & MICR) 2012-13 0.169 0.778 0.778- Immediate
9 Power saving due to resetting the Agitator shut at lower level in following chests of Stock Prepn-I i) Dry Broke chest agitator ii) Wet Broke Chest Agitator iii) PDF Recovered Fibre Chest Agitator
2012-13 0.1690 0.778 0.778- Immediate
10 Power saving due to resetting the Agitator shut at lower level in following chests of Stock Prepn-II i) Stock Prepn-II ii) Refined Pulp Pump Chest iii) PDF Recovered Fibre Chest
2012-13 0.160 0.738 0.738- Immediate
11 Power saving due to putting 32 nos. of Bulbs in RLK area OFF which were remaining "ON" for 12 Hrs/Day 2012-13 0.010 0.045 0.0450.005 0.111
12 Power saving due to removing Agitator from sludge tank in ETP 2012-13 0.115 0.532 0.532- Immediate
13 Power saving due to Debottlenecking /modification of PM-II steam and condensate system 2012-13 0.877 4.042 4.0420.800 0.198
14 Power saving due to replacement of PM-I Edge cutter existing pump and motor by Energy Efficient pump and motor Grundfos make.
2012-13 0.100 0.457 0.4570.080 0.175
15 Power saving due to replacement of PM-I Edge cutter existing pump and motor by energy efficient pump and motor - Grundfos make.
2012-13 0.099 0.454 0.4540.080 0.176
16 Timer provided for auto off of AC in BU-4 2012-13 0.020 0.090 0.0900.050 0.556
17 Evaporator WBL feed change from 5th to 4th effect and stop 4th effect extraction pump. 2012-13 0.367 0.165 0.1650.100 0.606
18 Bypass Heater mixer after EOP washer 2012-13 0.181 0.825 0.8250.100 0.121
19 Reduction in LP steam extraction pressure in TG-IV from 4.2 to 3.0 KG/Cm2. 2012-13 - -70.133 0.263 0.263 - Immediate
20 Steam saving in power generation by optimising steam extraction in TG III & IV 2012-13 - -5,817.200 18.542 18.542 - Immediate
SUB TOTAL (PAPER PLANT)3.190 10.397
5,887.333 18.805 29.202 1.871
ENERGY SAVING SCHEMES IMPLEMENTED IN THE YEAR
2011-12,2012-13 , 2013-14, 2014-15 & 2015-16 (contd…)
Slide No. 17J K PAPER LIMITED…….Creating Lasting Impressions
B) BOARD PLANT yearunits
Million
Rs.million
Tonsof coal
Rs.million
TotalSavings
Rs. million
TotalInvestmentRs. million
Pay backmonths
1
Power saving by reducing working hours of Halogen lamps in Wire part area by providing ON/OFF switch & educating operating crew.
2012-13 0.018 0.088 0.088 Immediate
2
Power saving due to replacement of motor of vacuum pump for Binip suction press by higher frame size motor.
2012-13 0.122 0.559 0.559 0.375 0.671
3
Power saving due to replacement of Broke Tower Agitator motor by lower rating motor.
2012-13 0.066 0.302 0.302 0.030 0.099
4
Power saving due to Middle layer stock chest (Tower No.4) Pumps & Motor replacement by low rating pump & motor
2012-13 0.170 0.783 0.783 - Immediate
5
Power saving due to installation of VFD in MG Predryer exhaust fan motor
2012-13 0.089 0.410 0.410 - Immediate
6
Power saving due to installation of soft starter for vacuum pump no. 4, all wire part of bottom layer.
2012-13 0.146 0.670 0.670 0.190 0.284
7
Power saving due to use of warm water through HP shower for cleaning of machine clothings
2012-13 0.155 0.713 0.713 0.180 0.252
8
Saving due to additional power generation on account of removing restrictions due to smaller manual valves control valve in steam line thus consming LP steam at available pressure.
2012-13 0.106 0.489 0.489 0.400 0.818
SUB TOTAL (BOARD PLANT) 0.872 4.014 - - 4.014 1.175
TOTAL (PAPER +BOARD PLANT)-2012-13 4.062 14.411 5,887.333 18.805 33.216 3.046
ENERGY SAVING SCHEMES IMPLEMENTED IN THE YEAR
2011-12,2012-13 , 2013-14, 2014-15 & 2015-16 (contd…)
Slide No. 18J K PAPER LIMITED…….Creating Lasting Impressions
List of Energy Conservation Projects implemented during 2013-14
Sr No Title of Energy Saving project implemented Annual Electrical Savings
achieved
Annual thermal
SavingsTotal
annual
savingsInvest.
Made
Rs. Million
Pay back
Months
Units Kwh Rs. Million Tons of
coal
Rs. MillionRs. Million
YEAR
2013-14
1 Power saving due to bypass of street B (for bottom) layer thicked pulp chest 178,317.00 0.882 0.882 0.06 0.81
2 Power saving due to Reduction of HP swoer nozzles of 1 MM dia to 0.9 MM dia
in Pm-1 & 2
21,900.00 0.110 0.110 0.04 4.36
3 Power saving due to Replacement of talcum dissolving tank agitators (2 nos.) by
energy efficient agitators.
112,425.85 0.568 0.568 0.04 0.85
4 Power saving due to Replacement of PM-II second press vacuum pump SPDP
motor (110 KW0 with new TEFC Energy effiecient motor
18,077.00 0.092 0.092 0.12 15.65
5 Power saving due to Replacement of Helogen lamps (1000 W X 6 nos. at PM-1
& 2 operarting floor by induction lamps (70 KW X 8 nos.)
23,500.00 0.118 0.118 0.07 7.00
6 Power saving due to Replacement of SV lamps by CFL at street lights in mill
premises and at boundary wall
30,473.85 0.154 0.154 0.09 7.72
7 Power saving due to installation of capacitor at various transformer PCC end 322,000.00 1.629 1.629 0.90 6.62
8 Power saving due to New Defleker Installed 683,128.50 3.873 3.8732.23 6.91
9 Power saving due to New Disperser Installed 98,373.60 4.520 4.52010.0 26.54
10Power saving due to Replacement of ST-B pulper dilution pump by energy
efficient small capacity Motor & Pump Installed50,924.00 0.408
0.408 0.075 2.20
11Power saving due to Replacement of ST-C pulper dilution pump by energy
efficient small capacity Motor & Pump Installed64,517.00 0.306 0.306
0.075 2.90
12Power saving due to Replacement of Top layer mixing chest Pump by energy
efficient small capacity Motor & Pump Installed14,904.00 0.075
0.075 0.012 2.06
13Power saving due to Replacement of Recovered fiber chest pump by energy
efficient small capacity Motor & Pump Installed18,216.00 0.091
0.0910.012 1.6
14 Power saving due to Vaccum Pump Optimaization 227,760.00 2.048 2.0480.023 0.24
TOTAL 2013-14 1,864,516.80 14.874 0.00 0.00 14.874 13.75
ENERGY SAVING SCHEMES IMPLEMENTED IN THE YEAR
2011-12,2012-13 , 2013-14, 2014-15 & 2015-16 (contd…)
Slide No. 19J K PAPER LIMITED…….Creating Lasting Impressions
YEAR
2014-
2015
PAPER PLANT & BOARD PLANT
Year of
Implementati
on
Annual Electrical Savings
AchievedAnnual Thermal Savings
Achieved
Total
Annual
Savings
Invest
made.
Payback
Months
Units Million Rs. Million
Tons of
Coal or
water or
steam
Rs. Million Rs. Million Rs. Million
1 Installation of Booster Pumps (2 Nos.) for increasing pressure of LP
showers
2014-15 478 2.04 2.04 1 6
2 Replacement of SV lamps by CFL at street lights in Mill premises and at
Boundary wall
2014-15 33.6 0.15 0.15 0.08 6.4
3 Replacement of Talcum dissolving tank agitators (2 nos.) by Energy
Efficiency Agitators
2014-15 126 0.56 0.56 0.5 11
4 Replacement of Halogen lamps (1000 W X 6 Nos.) at PM-I & PM-II
operating floor by Induction Lamps (70 KW X 8 Nos.)
2014-15 0.075 0.12 0.12 0.06 2
5 Replace use of Mill water for combi trimming by super clear water in PM-I. 2014-15 8400 0.15 0.15 0.12 10
6 HP shower Nozzles of 1 mm dia to be replaced by nozzles of 0.9 mm dia in
PM-I & PM-II.
2014-15 41160 0.74 0.74 0.58 9.4
7 Replacement of PM-II Second press vacuum pump SPDP motor (110 KW)
with new TEFC motor of Efficiency-1
2014-15 7.75 0.3 0.3 0.27 11
8 Installation Of Heat exchanger in PM1 steam condensate flash vapour 2014-15 4320 4.3 4.3 1.47 4
9 Replacement of fresh water by paper machine back water 2014-15 106080 1.7 1.7 0.53 3.7
10 Installation of new wedge filter for water of edge cutter nozzles in PM1 &
PM2
2014-15 0.12 0.12 0.15 15
TOTAL (PAPER +BOARD PLANT) 645.425 3.29 159960 6.89 10.18 4.76
ENERGY SAVING SCHEMES IMPLEMENTED IN THE YEAR
2011-12,2012-13 , 2013-14, 2014-15 & 2015-16 (contd…)
Slide No. 20J K PAPER LIMITED…….Creating Lasting Impressions
YEAR
2015-2016 PAPER PLANT & BOARD PLANT
Year of
Implementati
on
Annual Electrical
Savings ExpectedAnnual Thermal Savings
Expected
Expected
Total Annual
Savings
Invest
made.
Payback
Months
Units Million Rs. Million
Tons of
Coal or
wateror
steam
Rs. Million Rs. Million Rs. Million
1 Increase the production of bleach plant by using osscilatory back shower
in BF1,BF2,BF3 & BF4 for proper cleaning of wire face.
2015-16 408 2.24 2.24 0.8 5
2 Recovery Boiler MDT Level control using VFD 2015-16 42.048 0.23 0.23 0.25 13
3 Recovery BBAMT tank level control using VFD 2015-16 35.04 0.16 0.16 0.21 16
4 CFB No. 3 & 4 return cooling water line replacement 2015-16 34000 0.61 0.61 0.45 8
5 Power savings by providing auto start/stop in screening pit tank pump 2015-16 28.14 0.1 0.1 0.075 9
6 To install new LP shower pump (40 m3/hr) for breast roll & head box
shower in PM 2
2015-16 83.2 0.64 0.64 0.44 9
7 To connect decker filtrate line to suction of black liquor supply pump to
run bleach plant continuously
2015-16 0.5 2.77 2.77 0.23 1
8 Replacement of CFB no.3 start up vent valve 2015-16 0.53 0.58 0.58 0.28 6
9 Saving of steam in bleach plant by using hot water in BF1 & BF2 spray
shower
2015-16 57120 5 5 0.72 2.6
TOTAL (PAPER +BOARD PLANT) 189.458 4.48 91743 8.676 12.33 3.455
ENERGY SAVING SCHEMES IMPLEMENTED IN THE YEAR
2011-12,2012-13 , 2013-14, 2014-15 & 2015-16 (contd…)
Slide No. 21J K PAPER LIMITED…….Creating Lasting Impressions
ThemePower Saving by Installation of VFD
in CFB#4 Root Blowerpower block
Before After
CFB IV root blower 2 Nos (1 Working+ 1
Standby) were of air delivery capacity of 3762
M3/hr at 3400 mmwc pressure. It was running at
full load and consuming 30 KW power. But our
requirement was maximum 1800 m3/hr air at
1400 MMWC pressure.,
Trials conducted with spare available VFD and found
satisfactory operation at air delivery of 1800 m3/hr at
1400 MMWC. Vent opening has reduced from 38% to 18
% and power consumption reduced. In view of the
foregoing, we have installed new VFD in one of the two
Root Blowers .
Power savings KWh/Annum (22.05-15.5)X24X350=55020
Power cost Rs./KWh 4.61
Total savings Rs lacs/Annum 55020X4.61= 2.54
Investment Rs. Million Total Annual Savings Rs. Million Payback Period Months
0.16 0.25 7.70
ENERGY SAVING THEMES
Slide No. 22J K PAPER LIMITED…….Creating Lasting Impressions
Investment Rs. Million Total Annual Savings Rs. Million Payback Period Months
1.86 9.87 2.26
ThemePower Factor Improvement
From 0.82 to0.88Paper Plant
Before After
Plant load had been increased from 15 MW
to 16.28 MW .Due to increase in load,
power factor dropped from 0.88 to 0.82.
Power factor has been increased from 0.82 to 0.88 by using
capacitors at different PCCs and MCCs. The savings in power
is due to the reduction in heat losses
Reduction in power loss in cable from HT side breaker (6.6 KVA) to Transformer (P)=I²R=(57.115)² X 0.57
=1.88 KWh
Reduction in power loss in cable from transformer to PCC LT side (415V) (P)=I²R=(908.4)² X 0.35
=285.048 KWh
Reduction in power loss in cable from PCC to MCC(P)= I²R=(908.4)² X 0.04
=31.78 KWh
Power savings KWh/Annum (1.88+285.05+31.78)X24X350
=2677080Power cost Rs./KWH 4.61
Total savings Rs. lacs/Annum 2677080X0.8X4.61=98.73
ENERGY SAVING THEMES (contd…)
Slide No. 23J K PAPER LIMITED…….Creating Lasting Impressions
Investment Rs. Million Total Annual Saving Rs. Million Payback Period Months
0.890 3.97 2.70
Theme
Utilization of All Coal Fired Boilers
and Liquor Fired Boiler CBD & IBD
hot water in Causticizing & pulp
mill
Pulp Mill & Soda Recovery
Before After
All boiler CBD & IBD hot water of 90 deg. C
was drained @ 120 TPD(i.e. 120 m3/day) This
CBD & IBD hot water contains some amounts of
silica, which can be used as a process hot water
in pulp mill and Recovery plant.
CBD & IBD hot water of 90 deg C @ 120 TPD utilized
in pulp mill Causticizing hot water tank in which steam
was being consumed to raise the temperature of mill
water from 30 to 90 deg. C.
Water savings m3/Annum 120x350 = 42000
Water cost Rs./m3 5.00
Steam savings T/Annum 120X60X350/540=4667
Steam cost Rs./T 806
Total savings Rs. lacs/Annum 42000X5+4667X806=39.71
ENERGY SAVING THEMES (contd…)
Slide No. 24J K PAPER LIMITED…….Creating Lasting Impressions
Investment Rs. Million Total Annual savings Rs. Million Payback Period Months
0.06 0.21 3.42
Theme
Replacement of
Normal
Bulbs by CFL & LED
Electrical
Before After
Earlier we were using normal bulbs
at home of 100 W, 60W, & 40W,
which were consuming more power
at an average 200 W/hr per house
considering use of 8 hrs.
Normal bulbs have been replaced by less power consuming CFL
and LEDs of 9W, 11W, & 20W,Which reduced the power
consumption up to 160 W. At present the power consumption per
house is 40 W only. Daily use at an avg. 8 hrs and total no. of
houses where this replacement has done is 100. Power Saving
(200-40)=160 W.
Power savings KWh/Annum 160X8X100X350=44800
Power cost Rs./KWH 4.61
Total savings Rs.lacs/Annum 44800X4.61=2.07
ENERGY SAVING THEMES (contd…)
Slide No. 25J K PAPER LIMITED…….Creating Lasting Impressions
Investment Rs. Million Total Annual Savings Rs. Million Payback Period Months
NA 16.35 Immediate
Theme
Steam saving in power
generation by optimizing
steam extraction in TG 3 &TG 4
Power Block
Before AfterEarlier extraction steam was equally
distributed in both turbines and power
generated was almost equal
By optimizing the steam flow in TG 3 and TG 4 , total power
generation remains same and steam consumption reduced
to 2T/Hr
Parameter TG3(12 MW) TG4(12 MW) Parameter TG3(12 MW) TG4(12 MW)
Power 8.45 MWH 8.68MWH Power 6.63 MWH 10.45 MWH
MP 10 TPH 10 TPH MP 15 TPH 5TPH
LP 48TPH 38TPH LP 38TPH 48TPH
Condenser 13TPH 10TPH Condenser 8 TPH 13TPH
H P Steam 71TPH 58 TPH H P Steam 61TPH 66 TPH
Total Steam = 129 TPH, Power Generation = 17.12 MWH Total Steam = 127TPH, Power Generation = 17.08MWH
Saving of steam tons/Annum 2X24X350=16800
Coal consumption reduced
(Evaporation ratio= 3.8)
MT 16800/3.8= 4421
Cost of coal Rs./T 3700
Total Savings Rs. lacs/Annum 4421 X 3700=Rs.16357894
ENERGY SAVING THEMES (contd…)
Slide No. 26J K PAPER LIMITED…….Creating Lasting Impressions
ThemeReplacement of Broke Refiner by
DeflakerBoard Plant
Before After
We were running broke refiner for broke
handling.Broke refiner was very old design and
installed along with SAPPI machine.
Deflecker was installed in place of this broke refiner
for better broke treatment which is more energy
efficient and less power consuming. Earlier power
consumption was 210 KWh ,new Deflecker running
power consumption is 110 KWh
Power savings =210-110=100 KWh
Investment Rs. Million Total Annual Savings Rs. Million Payback Period Months
2.23 3.87 7.0
Power savings KWh/Annum 100 kwh x24 x350 =840000
Power cost Rs./KWh 4.61
Total savings Rs lacs/Annum 840000X4.61=38.73
ENERGY SAVING THEMES (contd…)
Slide No. 27J K PAPER LIMITED…….Creating Lasting Impressions
SAVING IN DISPERSER OLD(KWh) NEW(KWh) SAVING(KWh)
PRECOAT 119 73.4 45.6
BACK COAT 105 55.1 49.9
TOP COAT 107.1 92.7 14.4
CLAY 79.1 72.3 6.8
TOTAL 410.2 293.5 116.7
ThemeReplacement of Old Disperser by
New Disperser
Board Plant
Before After
We were running disperser of very old design
and installed along with SAPPI machine. It was
having DOL starter & dual speed motor.
Advanced version of new disperser with VFD controlled
installed which is more energy efficient and less power
consuming.
Investment Rs. Million Total Annual Savings Rs. Million Payback Period Months
10.0 4.52 26.5
Power saving KWh/Annum 116.7X24X350=980280
Power cost Rs./KWh 4.61
Total savings Rs. lacs/Annum 980280X4.61=45.2
ENERGY SAVING THEMES (contd…)
Slide No. 28J K PAPER LIMITED…….Creating Lasting Impressions
ThemePower saving due to Vacuum
Pump optimizationBoard Plant
Before After
Vacuum pump no. 1,3,4,6,7 & 9 were running.
It was decided to stop vacuum pump no. 7
which was used for Nipco Felt.
Vacuum requirement of Nipco was fulfilled by vacuum
optimization of vacuum pump no. 9 and stopping vacuum
pump no. 7. Energy saving was done. Total vacuum
pump load previous @ 1312 A, after stoppage of vacuum
pump no. 7 total load @ 1220 A., 1312-1220= 92A
Investment Rs. Million Total Annual Savings Rs. Million Payback Period Months
0.23 2.05 1.33
Power savings KWh/Annum (1.732X.415X92X.8)X24X350=444378.5
Power cost Rs./KWH 4.61
Total savings Rs Lacs/Annum 444378.5X4.61=20.50
ENERGY SAVING THEMES (contd…)
Slide No. 29J K PAPER LIMITED…….Creating Lasting Impressions
ThemeEnergy savings due to removing
of control valvesPaper Plant
Before After
Power consumption was higher due to the
friction losses in the lines due to present of
control valves.
All control valves were removed & VFD provided to
control flow of liquid. Power consumption reduced by 45
KW by avoiding the friction losses due to control valves.
Investment Rs. Million Total Annual Savings Rs. Million Payback Period Months
1.70 1.74 11.72
Power savings KWh/Annum 45X24X350= 378000
Power cost Rs./KWH 4.61
Total savings Rs Lacs/Annum 378000X4.61= 17.42
ENERGY SAVING THEMES (contd…)
Slide No. 30J K PAPER LIMITED…….Creating Lasting Impressions
i) Dry broke chest agitatorii) Wet broke chest agitatoriii) PDF recovered fiber chest Agitator
Investment Rs. Million Total Annual Savings Rs. Million Payback Period Months
NA 0.778 Immediate
(DETAILED TABLE IN THE NEXT SLIDE)
Power savings in dry
broke chest agitator
KWh/Annum 86798.16
Power savings in wet
broke chest agitator
KWh/Annum 35376.07
Power savings in pdf
recovered fiber chest
agitator
KWh/Annum 46691.42
Total Power Saved KWh/Annum (86798.16+35376.07+46691.42) =
168865
Power cost Rs. /KWh 4.61
Total savings Rs.lacs/Annum 168865X4.61 = 7.78
POWER SAVING DUE TO RESETTING THE AGITATOR SHUT AT LOWER STOCK
LEVEL IN FOLLOWING CHESTS OF STOCK PREP-1-
Slide No. 31J K PAPER LIMITED…….Creating Lasting Impressions
S.No Eq No PARTICULARS Units Before Scheme After schemes Savings Remarks
1 PM/c-1
Anticipatory working hours Hrs/Annum 8314 8314
2.1 821-23 Dry Broke chest Agitator2.1.1 Running Load KW 13.05 13.052.1.2 Working hours Hrs/Annum 8314 1662.8 20% RUNNING,
80% SHUT
2.1.3 Power consumption/Annum KWh/Annum 108497.7 21699.54 86798.162.1.4 Power cost Rs/KWh 4.61 4.612.1.5 Power cost saving Rs/Annum 500174.397 100034.8764 400139.5182.2 841-50 Wet Broke Chest Agitator
2.2.1 Running Load KW 8.51 8.512.2.2 Working hours Hrs/Annum 8314 4157 50% RUNNING,
50% SHUT
2.2.3 Power consumption/Annum KWh/Annum 70752.14 35376.07 35376.072.2.4 Power cost Rs/KWh 4.61 4.612.2.5 Power cost saving Rs/Annum 326167.3654 163083.6827 163083.6827
2.3 841-50 PDF Recovered Fiber chest Agitator2.3.1 Running Load KW 6.24 6.242.3.2 Working hours Hrs/Annum 8314 831.4 10% RUNNING,
90% SHUT
2.3.3 Power consumption/Annum KWh/Annum 51879.36 5187.936 46691.4242.3.4 Power cost Rs/KWh 4.61 4.612.3.5 Power cost saving Rs/Annum 239163.8496 23916.3849 215247.465
3 TOTAL POWER CONSUMPTION KWh/Annum 231129.2 62263.546 168865.6544 TOTAL POWER COST Rs/Annum 1065505.612 287034.9471 778470.665
7.78 LACS
POWER COST SAVINGS DUE TO REDUCTION IN STOCK PREPARATION CHEST
AGITATOR RUNNING TIME PM-1
Slide No. 32J K PAPER LIMITED…….Creating Lasting Impressions
THANK YOU……