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Unit - Bhadrachalam
Company Profile
Unit-Bhadrachalam of PSPD, a Division of ITC Ltd, is Indias largest and most
technologically advanced Pulp & Paper manufacturing facility.
7.4 Lakh TPA Paper and Paper Board & 3.50 Lakh TPA Bleached pulp capacity.
Core Competency:
>99% self sufficiency through in-house co-generation.
1,42,000 hectares of plantation for fiber sustainability
ISO 9001, 14001 an OHSAS 18001, BRC-IoP & FSC-CoC Certified
Carbon Positive for 8 consecutive years.
Water Positive for 11 years in a row.
Waste recycling positive for 6 years in a row.
26,731 MT of waste paper recycled through WOW initiative (Wealth out of Waste).
TPM Methodology A way of life
Building a sustainable, secure and inclusive future through Triple Bottom Line approach Economic, Environmental & Social
Cooking
Washing &
Screening
Bleaching
Finishing
House
Godown &
Dispatch
Paper
Machine
Paper
&
Paper
Board
Chemicals
Soda Recovery
Evaporators
Soda Recovery
Boilers
Water
Utilities
Water
Treatment
Lime
Kiln
Causticising
Power & Steam
Steam
Generators
Turbine
Generators
Compressed Air
Compressors
Electrical
Thermal
(Million kWh) (Tons of Coal)
Savings
(Rs Million)
Year 2012-13
1
0.003
0.008
0.092
0.230
0.048
0.120
0.037
0.093
0.230
0.575
0.270
0.675
0.433
0.173
0.213
0.533
0.0004
0.001
10
0.088
0.220
11
0.063
0.158
Stoppage of UF pump and fully loading the colony water pumps for cl2
dosing
0.278
0.695
12
Electrical
Thermal
(Million kWh) (Tons of Coal)
Savings
(Rs Million)
Year 2012-13
Power consumption reduction
0.079
0.198
14
0.152
0.380
15
0.051
0.128
0.001
0.003
1.7
4.250
0.260
13
16
17
Top layer and middle layer refiner bypass during DKL and DKP
product run
18
0.104
19
0.009
0.023
20
0.09
0.225
21
0.029
0.073
22
0.001
0.003
23
On/off control for lighting of ESP ground floor and rest of the floor
0.007
0.018
Electrical
Thermal
(Million kWh) (Tons of Coal)
Savings
(Rs Million)
Year 2012-13
-
24
0.4
25
0.96
2.4
0.576
1.44
Total
5.65
14.1
26
~ 645 kW saving
1% of the Electrical Energy consumption
Electrical
Thermal
(Million kWh) (Tons of Coal)
Savings
(Rs Million)
Year 2011-12
27
Power saving on couch pit pump & agitator by interlock based on level
control
0.024
0.48
28
0.04
0.8
29
0.052
1.04
30
0.032
0.64
31
0.08
1.6
32
0.016
0.32
33
Timer Switch provided for avoiding the power consumption for lighting
0.016
0.32
34
0.2
35
0.002
0.04
Electrical
Thermal
(Million kWh) (Tons of Coal)
Savings
(Rs Million)
Year 2011-12
36
0.192
3.84
37
0.008
0.16
38
0.08
1.6
39
0.008
0.16
40
0.058
1.16
41
0.048
0.96
42
3200
6.14
43-58
Kaizens 43 58 (Cumulative)
0.016
0.25
Total
0.87
3200
8.32
No. of Zero
Investment
Projects
Annual Energy
Saved (Million
kWh)
Annual
Energy
Saved
(MT Coal)
Savings
(Rs.
Million)
2011-12
32
0.87
3200
8.3
2012-13
26
5.65
14.1
Total
58
6.52
3200
22.4
Total 58 projects with ZERO investments implemented in 2 years 201112 & 2012-13 resulted saving of Rs. 22.4 Million.
ZERO investment projects are mostly coming from shop floor / TPM where
Every employee irrespective of level contributing in Energy & Resource
Conservation.
Electrical
(Million kWh)
Thermal
(Tons of
Coal)
Savings
(Rs.
Million)
Investment
(Rs. Million)
0.09
0.22
0.28
0.04
0.11
0.2
0.11
0.28
0.25
0.06
0.14
0.25
0.09
0.22
0.25
0.17
0.42
0.24
0.04
0.1
0.25
0.05
0.13
0.25
0.05
0.12
0.33
10
2.8
7.0
11
Electrical
(Million kWh)
Thermal
(Tons of
Coal)
Savings
(Rs.
Million)
Investment
(Rs. Million)
0.72
1.8
34
3180.5
5.96
0.47
1.2
11
12
13
14
1.22
3.06
15
0.68
1.7
16
0.64
1.6
10
17
0.4
18
0.56
1.4
19
0.72
1.8
20
0.64
1.6
8.5
21
Installation of Lightpipe
0.02
0.04
0.1
Electrical
(Million kWh)
Thermal
(Tons of
Coal)
Savings
(Rs.
Million)
Investment
(Rs. Million)
1.4
3.5
14.8
22
23
0.264
0.66
24
0.004
0.0104
0.25
25
10400
7.3
50
11.97
13580
43.2
180.4
Total
Annual
Electrical
Savings
achieved
Units
Million
Year
Annual thermal
savings
Rs
Tons of Coal
Million
or oil
Rs
Million
Total Annual
Savings
Rs Million
Investment
Made
Rs Million
2010-11
12
4.22
10.5
3180
5.96
16.5
47.8
2011-12
41
6.95
17.38
3200
6.14
23.52
65.6
2012-13
30
7.32
18.3
10400
7.3
25.6
67.1
Total
83
18.5
46.2
16780
19.4
65.6
180.5
Efforts for efficiency improvement at various stages has maintained reducing trend of specific
energy consumption
1.4%
*
Excluding energy consumption for new facilities / projects which are commissioned in FY 2012-13.
Efforts for efficiency improvement at various stages has maintained reducing trend of specific
energy consumption
Benchmarking
Specific Primary Energy (GJ/T)
Benchmark Reference:
Centre for Science & Environment study published in 2010 for Pulp & Paper sector
Benchmarking
Company
Capacity
ADt
Production
ADt
Specific
Energy
GJ/ADt
Energy
BAT
GJ/ADt
MT CO2
released/
ADt
MT CO2 /ADt
(accounting for
sequestration)
Deviation from
Energy BAT (in
per cent)
ITC Ltd.,
PSPD
526950
414714
29.4
22.0
1.6
-4.7
34
BILT
738500
549179
43.2
24.0
3.0
2.1
80
TNPL
290000
245836
42.6
24.5
2.7
2.4
74
West Coast
181500
169891
35.7
23.4
1.9
1.9
53
APPM
174650
180681
47.7
24.5
2.7
2.7
95
JK
240000
198072
43.8
23.6
2.3
-0.3
86
SPB
115000
124312
35.3
23.2
2.9
2.4
52
HPC Navagoan
100000
115925
42.5
27.5
2.7
2.7
55
Source: Extract from the study report Balance of the Future (2010) by Centre for Science &
Environment on Indian Pulp & Paper Industry on Energy & Emissions.
Projects in progress
Sr.
No.
Project Description
Annual Energy
Saving (Million
Units)
0.48
0.16
Annual
Monetary
Saving (Rs.
Million)
1.2
0.4
0.64
1.6
0.4
0.72
1.8
Investment
(Rs. Million)
2.0
1.0
3.0
0.3
3.0
0.56
1.4
0.96
2.4
3.92
9.8
2.0
7.0
18.3
Continuous focus to identify potential energy saving opportunities through energy audits
Innovative Projects
1. Vacuum system optimization at Paper Machine
Objective: To reduce energy consumption at board machine by optimizing the
vacuum system.
Trigger:
Operating 12 nos. vacuum pumps for the board machine
Total power consumed is 1333 kW.
Each vacuum pump attached to one separate application in wire part &
press part.
Vacuum system operated with air bleeding based on GSM & process
variation
Innovative Project 1
Actions taken:
Applications with similar vacuum levels combined
Connected these applications to vacuum pumps with equivalent vacuum
generation
Available vacuum line interconnections valves opened which resulted in one
vacuum pump spare
Spare vacuum pump overhauled & scales removed
All vacuum pumps overhauled in an orderly manner
Further fine tuning of vacuum connections resulted in stoppage of 3 operating
vacuum pumps
Innovative Project 1
Application
Vacuum
Pump #
VP-1
VP-2
VP-3
VP-4
VP-5
VP-6
VP-7
VP-8
VP-9
VP-10
VP-11
VP-12
Total
Rated Motor
Power in kW
Multi chambers of all
layers
TL & BL Transfer, Flat
suction boxes
ML flat & transfer box
Suction couch zone-1
Suction couch zone-2
Suction pick up
Suction press
1st press top felt
1st press bottom felt
2nd press bottom felt
2nd press top felt
3rd press top felt
Power before
project (kW)
75
59
160
90
160
160
132
160
132
132
132
132
132
1597
148
52
141
127
114
144
80
99
115
134
120
1333
Power after
project (kW)
1047
1047
Innovative Project 1
: Rs. 52 Lakhs
Other Benefits :
Vacuum system network improved with interconnection of similar applications &
vacuum pumps.
Achieved more operational flexibility due to spare pumps in system.
Reduced cost for spares & maintenance due to less no. of operating vacuum pumps
Innovative Project
2. Foul Condensate Stripping
Objective: To extract the heat energy & water wasted with Foul condensate
Trigger:
Foul condensate drained without any reuse
Heat content in the foul condensate also wasted
Foul condensate also contribute to COD at ETP
Innovative Project 2
Digester
Foul Cond & Vacuum
pump seal water to drain
LP Steam
Causticizer
Plant
Fresh
Water
Hot
Water
Drain
Pulp mill
Innovative Project 2
Evaporator
3&4
Digester
PCFT 1,2,3
LP Steam
Stripper
Stripped
Condensate
Causticizer
Plant
Vapour
DM Water
DM Water
Top
Condenser
Trim
Condenser
Hot DM Water
Hot DM Water
NCG for
Burning
Innovative Project 2
: 6.83 TPH
: 3.09 TPH
: 9.93 TPH
Innovative Project 3
3. Refiners Optimization at Board Machine
Objective: Power consumption reduction for refiners at Board Machine.
Trigger:
Craft board manufactured on the machine for 4 days/month
Machine having total 7 nos. of Refiners
All refiners operated to maintain 38-40SR for pulp
Critical Quality parameter to be maintained as desired for the product
Total operating power consumption 2006 kW
Innovative Project 3
Actions taken:
Studied the SR requirement & identified extra refining for the desired output
Experience of earlier successful trial on another craft grade product was replicated
with change in refiner operating practices
Monitored the critical parameters against requirement
5 refiners could be bypassed during this product run
Refiner #
DDR 1
DDR 4
DDR 2
DDR 3
WAR 3
DDR 5
TDR
Total
Rated Motor
Power in kW
450
450
450
450
250
350
250
2650
Innovative Project 3
: Rs. 38 Lakhs
Other Benefits :
Increased life of tackles for the switched off refiners.
Environmental Projects
1. Effluent Treatment Plant Upgradation
Parameter
With Old
Surface
Aeration
DO, mg/lit
1.5
3.5
COD, mg/lit
220
180
BOD, mg/lit
27
24
Environmental Projects
2. Foul Condensate Reuse through Stripper
With New
Surface
Aeration
Environmental Projects
3. CO2 Sequestration through plantations
Environmental Projects
4. Wealth Out of Waste (WOW)
CERs
677
15,000
679
40,000
890
40,000
806
20,000
2241
50,000
3890
75,000
Employee Involvement
Ensuring involvement of all employees including middle and top management
Ideas / suggestions from employees for improvement - PQCDSM
Capture benefits through BTS
Reward & Recognition
Category
No. of Suggestions
implemented 2012-13
Productivity
379
Qualtiy
623
Cost
391
Delivery
360
Safety
1486
Morale
1268
Combined PQC
2466
Total
6973
Process
Responsibility
Idea/suggestion
All employees
Energy Cell
Feasibility check
Technology Selection
Capital Scheme
Department/Energy Cell
Procurement
DMT/JH Leader
Implementation
Department
Energy Cell
10
Certification of savings
Energy Cell
No. of Findings
ISO 9001
ISO14001
OHSAS 18001
QMS
23/4/ Control of document found not
2013 adequate in few case for Ex: at
Chipper house, Sop for metal
detector no doc number, no
revision no, no date of
effectiveness
Category of
Finding
Corrective Action to
Eliminate Basic
Cause of
Nonconformity
Observation
Chipper
House
Review mechanism
of SOP to be
strengthened
SOP is being
revisited
EMS
23/4/ Management program formulation Observation FH # 6
2013 is not linked with significant
aspect identified in few case for
Ex:1. use of diesel operator
clamper in FH06 -no replacement
planned with battery operated
equipment.
OHSAS
23/4/ Storage of Reels more than the
2013 specified height observed near
FH#4 WIP Reels (Hold) about 3
stacks observed
Observation
It is not considered
earlier
Corrective Action to
Eliminate Basic
Cause of
Nonconformity
Management
Programmes will be
linked to Aspects
and Impacts & Risk
Assessment for EMS
/SMS.
SRB-5 with capacity of 400 T/day BLS commissioned in 2011-12 to increase renewable energy
Year 2008-09
% Renewable Energy
Year 2012-13
% Fossil Energy
Utilisation of Waste
100% Fly ash utilisation by way of manufacture of Fly Ash Bricks, remaining sold to
Cement manufacturing units.
Lime sludge recycled with Lime Kiln.
Andritz Press sludge is utilised by external agency for card Board manufacturing & egg
tray manufacturing
Effluent Treated discharge for irrigation / plantations.
100% of Solid Waste is utilized.
Fly Ash utilization Trend
3
-1
12
20
Description of
Best Practice
%
improvement
Buying only 5
star rated ACs
0.9 kW/TR
0.8 kW/TR
11
Buying only
EFF1 class
motor
Buying only T5
Tube-lights
94.5% efficient
motors
91% efficient
motors
36
28
22
Type of inputs /
projects
provided to the
vendor/
associate
Use of highest
energy efficient
equipments
Use of highest
energy efficient
equipments
Use of highest
energy efficient
equipments
Awareness programs for Colony Residents & school children for energy conservation
Thank you