CENTURY RKSHARMA

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CENTURY PULP AND PAPER LALKUA, NAINITAL ( A BK BIRLA GROUP OF COMPANY ) ISO –9001 – 2000 AND ISO -14001 CERTIFIED COM PANY AN INTEGERATED PULP & PAPER UNIT 31320 TPA RAYON GRADE UNIT 37250 TPA WOOD BASE WRITING PAPER 84600 TPA BAGASSE BASE PAPER ECO MARKED BAGASSE PAPER

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CENTURY PULP AND PAPER POWER ARRANGEMENTS 6.8 MW TG SET 21 MW TG SET 7.5 MVA CONTRACT DEMAND FROM UPCL 6,10,000 UNITS /DAY

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CENTURY PULP AND PAPER THERMAL ENERGY ARRANGEMENTS 23 TPH 46 Kg/cm2 FBC C F B 3 NO 25 TPH 46 Kg/cm2 SPREADER STOCKER CFB 1 NO 50 TPH 62 Kg/cm2 FBC C F B 2 NO 40 TPH 46Kg/cm2 CHEM REC BOILER( BHEL ) 1 NO 50 TPH 62Kg/cm2 CHEM REC BOILER( ABL ) 1 NO

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ELECTRICAL ENERGY (KWH) : 2001 - 2004

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ELECTRICITY CONSUMPTION AND COST 2001-02 2002-03 2003-04 PURCHASED UNITS (Lac kwh/yr) 239.83 192.27 159.73 COST ( Rs lacs/yr) 1399 1177.84 746.84 OWN GENERATION THROUGH DG SETS UNITS (Lac kwh/yr) 47 34.81 19.37 COST ( Rs lacs/yr ) 219.44 182.88 117.13 THROUGH STEAM TURBINES UNITS ( Lac kwh/yr) 1754.58 1865.88 2001.13 COST ( Rs lacs/yr) 1937.58 1974.96 1903.86

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TOTAL CONSUMPTION OF ELECTRICITY 2001-02 2002-03 2003-04 UNITS (Lac kwh/yr ) 2041.41 2092.96 2180.23 COST (Rs lac/yr) 3556.02 3335.68 2767.83

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THERMAL ENERGY CONSUMPTION FOR PROCESS 2001-02 2002-03 2003-04 COAL HEAT VALUE (Mkcal/yr) 728037 653007.6 651336.7 BLACK LIQUOR HEAT VALUE 659445 704815 711616.75 PITH HEAT VALUE 60501 78867 74641.5 TOTAL 1447983 1436690 1437595

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APPROACH FOR ENERGY CONSERVATION AWARENESS – EDUCATION & TRAINING CAPACITY UTILIZATION INCREASED OPTIMIZATION OF VOLTAGE OPTIMIZATION OF FREQUENCY OPTIMIZATION OF OPERATING PROCEDURES THRUST ON RECYCLE & WASTE MINIMIZATION FINE TUNING OF PLANTS & EQUIPMENTS INSTALLATION OF VFD”S ADOPT ENERGY EFFICIENT LIGHTING USE OF EFFICIENT EQUIPMENT TECHNOLOGY UPGRADATION ASSESSMENT AND MONITORING

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ASSESSMENT & MONITORING AUDIT CONDUCTED BY CII : APRIL2003 39 ENERGY SAVING SCHEMES IDENTIFIED AUDIT CONDUCTED BY INGERSOLL RAND : SEPT 2003 8 SCHEMES IDENTIFIED AUDIT CONDUCTED BY ECKO PUMPS FOR PAPER M/C III VACUUM SYSTEM : OCT2004 4 SCHEMES IDENTIFIED AUDIT CONDUCTED BY DSCL FOR ENERGY COST REDUCTION IN FEB 2004 : 4 SCHEMES IDENTIFIED MOTOR EFFICIENCY ASSESSMENT BY VBI SYSTEMS PLANT TECHNICAL AUDITS BY INDEPENDENT COUNSULTANTS : AUG 2004

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EC CELL PRESIDENT LOSS IDN COM ISO 14001/ ISO 9001/QC * PRODUCTION * TPM SEC * 3 MEMBERS * MR. * POWER HOUSE * PILAARS * CROSS FUNCT * SYSTEM COORD. TEAMS * ELECT&INST * OVERLAPPING * QUALITY CIRC COMMITTEES * ENV & WATER * STO & PUR * PURTA ORGANISATIONAL SET UP FOR ENERGY CONSERVATION TPM

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ENERGY CONSERVATION CELL FUNCTIONS COORDINATE STEAM & POWER REQUIREMENTS STUDY VARIANCE IDENTIFY ENERGY CONSERVATION OPPURTUNITIES REVIEW ENERGY AUDIT FINDINGS STRATEGY INCREASE AWARENESS ACHIEVE MAXIMUM PLANT EFFICIENCY INDUCT LATEST TECHNOLOGY ENSURE TIME BOUND IMPLEMENTATION

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TPM ENHANCE PLANT EFFICIENCY A ZERO BASED APPROACH

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0 LOSS FAILURE DEFECT DOUBT ACCIDENT BREAKDOWN

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AUTONOMOUS MAINTENANCE ( JISHU HOZEN ) MY MACHINE I MAINTAIN

EDUCATION AND TRAINING: 

EDUCATION AND TRAINING SKILL DEVELOPMENT : TRAINING PROGRAMME TPM AWARENESS 118 TECHNICAL 722 BEHAVIORAL 99 FIRE AND SAFETY 209 ON JOB TRAINING THROUGH ONE-POINT-LESSON SHEET

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TPM RE- DEFINED

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LOSS IDENTIFICATION COMMITTEE HIGHLIGHT PROCESS INEFFICIENCIES CHECK LOSSES OF ALKALI,FIBRE,WATER, CHEMICAL AND STEAM ARRANGE CORRECTIVE MEASURES

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ISO 9001-2000 CONTINUAL IMPROVEMENT WASTE MINIMIZATION ISO14001 CONSERVATION OF RESOURSES ADOPTING CLEANER TECHNOLOGIES ALTERNATIVE FIBRE RESOURSES UTILIZATION OF WASTE LIME MUD UTILIZATION OF WASTE PITH QUALITY CIRCLE 19 CIRCLES OPERATIVE

ANNUAL SAVING IN POWER UTILISATION WITHOUT INVESTMENT : 

ANNUAL SAVING IN POWER UTILISATION WITHOUT INVESTMENT

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NO / LOW INVESTMENT SCHEME 2001-02 2002-03 2003-04 NO OF SCHEMES 2 8 9 SAVINGS / ANNUM KWH (LACS) 11.82 8.914 36.755 COAL EQ (TONS) - 16366 32550 Rs ( LACS) 24.65 312.45 658.64 INVESTMENT 2.11 - - TOTAL Rs 995.74

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ENERGY CONSERVATION SCHEMES NO / LOW INVESTMENT ( 2001 – 02)

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ENERGY CONSERVATION SCHEMES NO / LOW INVESTMENT ( 2002 – 03)

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NO / LOW INVESTMENT ( 2002 – 03)

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NO / LOW INVESTMENT ( 2002 – 03)

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NO / LOW INVESTMENT ( 2003 – 04)

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VARIABLE FREQUENCY DRIVES

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ENERGY CONSERVATION SCHEMES VFD 2001-02 2002- 03 2003-04 TOTAL NOS INSTALLED 16 11 25 INVESTMENT 39.3 8.06 31.03 SAVINGS /ANNUM KWH (LACS) 21.2 3.66 11.36 Rs (LACS) 42.4 8.22 22.72 73 . 34 LACS UNIT COST Rs 2.00

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Q(LPM) Q1 Q2 P2 P1 P mtr of wc VFD - FANS, BLOWERS & PUMPS AFFINITY LAWS Q1 = N1 Q2 N2 2 P1 = N1 P2 N2 3 HP1 = N1 HP2 N2

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THROTTLING VS SPEED CONTROL

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.2 .4 .6 .8 1.0 100 80 60 40 20 Fan/ Pump Input Power Q(LPM) Per unit flow discharge A B A- damper control = 0.4 +0.6Q B -VSD control = Q3 ASSUMPTIONS : Static Head on fan/ pump is negligible. Fan/pump input is 0.4 Per Unit under full valve/ damper closed condition. POWER REQUIREMENT VSD VS VALVE THROTTLING

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ENERGY CONSERVATION SCHEMES ELECTRICAL VFD (2001-02)

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ELECTRICAL VFD (2002-03)

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ELECTRICAL VFD (2003-04)

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ELECTRICAL VFD (2003-04)

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SLD BAGASSE PAPER M/C

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SLD BAGASSE PULP

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SLD RGP MCS

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SLD WPP CCS ETP TR 3

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TG 2 21 MW TG 1 6.8MW 132/11 KV BPULP B M/C RGP WPP 10MVA 11/11KV

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HARMONICS STUDY FINDINGS TG1 TG2 DG GR TR 1 GR TR 2 Vthd 1.93 3.80 2.98 0.72 1.78 Ithd 3.52 3.63 3.42 1.17 1.78 PERMITTED VALUES 5 %

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OTHER ELECTRICAL SCHEMES FOLLOWED: PROVISION OF LOAD TRANSFER FROM GRID TO TG WITHOUT INTERRUPTION TO UTILIZE SOURCES PREVENT IDLE RUNNING OF EQUIPMENTS BY INTERLOCKING OF PUMPS & AGITATORS EFFECTIVE CONTROLS LIKE ONE PB FOR COMPLETE GROUP EQUIPMENTS OF PLANT SWITCH OFF EQUIPMENTS THROUGH TIMERS DELTA - STAR FOR LIGHTLY LOADED MOTORS NEUTRAL COMPENSATORS FOR UNBALANCE LOADS LED”S FOR INDICATING LIGHTS LOW LOSS HRC FUSES USE OF ENERGY SAVERS FOR LIGHTING CIRCUITS USE OF PHOTO CELLS FOR STREET LIGHTS SPLITTING OF CIRCUITS FOR BETTER CONTROL

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TOTAL SAVINGS / ANNUM ( FOR LAST THREE YEARS) KWH (LACS) 4.62 Rs (LACS) 9.24 INVESTMENT Rs (LACS) 9.65

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ENERGY CONSERVATION SCHEMES ELECTRICAL OTHERS

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ENERGY CONSERVATION SCHEMES ELECTRICAL OTHERS

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TOTAL SAVINGS THERMAL / PROCESS 2001-02 2002-03 2003-04 INVESTMENT 77.55 78.90 853.79 SAVINGS KWH (LACS) 29.02 27.69 19.73 COAL EQ.(TONS) 6765.7 5500 3593 Rs (LACS) 235.48 160.58 574.46 KWH = Rs 2.00 COAL/TON = Rs1800 970.52

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ENERGY CONSERVATION SCHEMES THERMAL / PROCESS 2001 - 02

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THERMAL / PROCESS 2001 – 02 contd…

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THERMAL / PROCESS 2002 – 03 contd…

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THERMAL / PROCESS 2003 – 04

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THERMAL / PROCESS 2003 – 04 contd…

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TOTAL ENERGY SAVINGS FOR LAST 3 YEARS 2001- 02 2002- 03 2003- 04 NO OF MEASURES 8 34 47 ( IMPLEMENTED ) INVESTMENT (LACS) 77.85 138.8 893.85 SAVINGS ACCHIEVED KWH (LACS) 38.94 66.27 78.614 THERMAL (FUEL ) 11063 87900 143608 ( MkCAL ) Rs LACS 205.61 541.17 1141.75 1888.53

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RGP 44 PAPER 92 SPECIFIC POWER CONSUMPTION TREND

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RGP 1.468 PAPER 1.346 SPECIFIC STEAM CONSUMPTION Mkcal / TON

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INNOVATIVE SCHEMES SUBSTITUTION OF FURNACE OIL UTILIZATION OF SOLID WASTE OPTIMIZATION OF GENERATION

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RECALCINE LIME SLUDGE LIME PRODUCER GAS PLANT ENERGY THROUGH RFO HIGH COST FUEL

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RECALCINE LIME SLUDGE LIME PRODUCER GAS PLANT INVESTMENT Rs 338.0 LACS SAVINGS IN2003-04 Rs 196.0 LACS ENERGY THROUGH COAL - LOW COST FUEL

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BAGASSE STORAGE

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DE - WATERING PITH PRESS WASHING BAGASSE CONTINUOUS DIGESTER WET PITH 80 % MOISTURE

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BAGASSE WASHING CONTINUOUS DIGESTER DE - WATERING PITH PRESS DE – WATERING PITH PRESS 50 % MOISTURE PITH INVESTMENT : Rs 348.29 LACS ANNUAL SAVINGS : Rs 134 LACS

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PRDS PRDS 62 110.5 27.28 80.75 2.5 4.7 68.94 33.17 37.41 15.8 46 B5 B6 A BL 130.6 B4 BH EL B1 70.65 3.5 10.5 3.5 10.5 PRDS 15.0 PLANT PLANT PLANT PLANT 21 MW 6.8MW OPTIMIZATION OF GENERATION POWER GENERATION 23.5 MW COND

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PRDS PRDS 62 111.2 23 73.43 14.71 3.36 68.94 33.42 35.52 2.0 46 B5 B6 A BL 133.4 B4 BH EL 50.6 3.5 10.5 3.5 10.5 PRDS 20.27 PLANT PLANT PLANT PLANT 21 MW 6.8MW OPTIMIZATION OF GENERATION POWER GENERATION 22.0 MW B1 COND

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OPTIMIZATION OF GENERATION SAVINGS FULL EXTRACTION AT 10.5 Kg/cm2 REDUCED PRDS FLOW HIGHER STEAM FOR COGEN IMPROVED EFFICIENCY REDUCED VENTING OF STEAM STOPPED ONE CFB DEARATOR STEAM REDUCED ONE BOILER FEED PUMP STOPPED LOAD ON COOLING TOWER REDUCED COAL @2700MT/MONTH Rs 583 LACS POWER @350 KWH Rs 56 LACS TOTAL Rs 639 LACS

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ENVIRONMENTAL MANAGEMENT GREEN PRACTISES SYSTEMATICALLY ADOPTED AND INTEGRATED INTO OVERALL PRODUCTION PROCESS ENZYMATIC PRE BLEACHING BIO REFINING OF PULP COOKING AIDS IN DIGESTER FARM FORESTERY CONSERVATION OF RESOURSES SOLID WASTE MANAGEMENT REQUIREMENT FOR CORPORATE RESPONSIBILITY FOR ENVIRONMENT PROTECTION

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WATER CONSUMPTION TREND KL/TON 24

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RECYCLING OF BLEACHING BACK WATER RECYLING OF SHEETING M/C BACK WATER RECIRCULATION OF COOLING WATER RECLAMATION OF PAPER M/C & STOCK BACK WATER WATER CONSERVATION ACHIEVED THROUGH 23 SCHEMES IMPLEMENTED IN LAST THREE YEARS

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CHLORINE CONSUMPTION KG/TON 24

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FUTURE PLANS

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    FUTURE PLANS CONTD….

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FUTURE PLANS CONTD…. SCHEMES WITH AN INVESTMENT OF Rs 125.08 LACS AND SAVINGS OF Rs 113.59 LACS

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SCHEMES IN HAND INSTALLATION OF WASTE FIRED BOILER 2000 LACS INSTALLATION OF BLACK LIQ CLARIFIER 120 LACS RETROFITTING OF LIME KILN 374 LACS AUTOMATION OF PULP MILLS BY DCS 300 LACS

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AWARDS & RECOGNITIONS SELECTED AS A MODEL UNIT BY CPCB/NPC FOR WASTE MINIMIZATION AWARDED CERTIFICATE OF APPRECIATION FOR ADOPTING CLEANER PRODUCTION TECHNOLOGY UNDER UNEP ECO MARK FOR BAGASSE BASE PAPER BY BUREAU OF INDIAN STANDARDS GREENTECH INDO GERMAN AWARD FOR ENVIRONMENTAL EXCELLENCE : 2002 BEST ENERGY CONSERVATION AWARD BY INDIAN PAPER MANUFACTURERS ASSOCIATION : 2003 AND 2004 AWARDED ENERGY EFFICIENT UNIT FOR 2004 BY CII AWARDED FIRST PRIZE FOR ENERGY CONSERVATION FOR 2004 BY MINISTRY OF POWER