Presentation on “Excellence in Energy Management

Presentation on
“Excellence in Energy Management-2017”
Company Profile
Kuantum Papers is in the business of production and marketing of writing
& printing paper, while conserving precious resources & protecting the
environment.The mill was established in 1979-80, in a village - Saila
Khurd, in District Hoshiarpur, in the state of Punjab, India, with an aim to
utilize wild Agro vegetations like Sarkanda Grass and Kahi Grass, and
Agro-residues such as Wheat straw and Bagasse, to make writing and
printing grades of paper. These Agro vegetations were at the time being
burnt in the fields, leading to environmental pollution. Thus by creating an
application for their use, we helped reduce environmental degradation
substantially. It has now reached a level of 120000 TPA in paper
production. The company employs approximately 1400 people, and the
annual sales turnover touches Rs. 7000 million .
Plant Equipment Details:Utility Details
Boiler Section
Power Section
Boiler-02
26 TPH
35 Kg/cm2
TG-02
5 MW
Condensate
Boiler-03
26 TPH
35 Kg/cm2
TG-03
1.12 MW
Back Pressure
Boiler-04
60 TPH
67 Kg/cm2
TG-04
10 MW
Back Pressure
Chemical Recovery
21 TPH
Boiler
67 Kg/cm2
Grid S/S Supply
at 66 KV
10.5 MVA
Pulp Mill Details
Agro Section
Agro Street
160 TPD
Hardwood Section
Hard Wood
60 TPD
Plant Equipment Details:Paper Machines
Other Sections
Paper Machine-01
25 TPD
Effulent Tratment Plant 20000m3/day
Paper Machine-02
30 TPD
Chemical Recovery
Plant
200 TPD
Paper Machine-03
100 TPD
Lime Kiln Plant
40 TPD
Paper Machine-04
250 TPD
Fluidized Bed Reactor
85 TPD
Achievement:- In Terms of Savings
ENERGY CONSERVATION PROJECTS DURING 2014-2015
POWER CONSUMPTION (KW)
SR.
NO
PROJECT
AREA
1 PCC PUMP
PM # 4
BSW#0 VAT DILUTION
2
PUMP
PULP
MILL
BSW#1 VAT DILUTION
3
PUMP
PULP
MILL
BSW#2 VAT DILUTION
4
PUMP
PULP
MILL
BSW#3 VAT DILUTION
5
PUMP
PULP
MILL
DECKER WASHER
6
CLEANING SHOWER
PULP
MILL
SAVING IN SAVING IN
BEFORE
AFTER
KWH (PER
Rs.
MODIFICATION MODIFICATION ANNUM) MILLIONS
709
56.2
54.4
52.5
52
21.9
518
45
44
37
37
10
REMARKS
1512720 10.6 Pump Impeller Trimmed.
88704
82368
122760
118800
94248
0.6
100HP Motor Replaced With 75HP
Motor & New Energy Efficient
Pump Installed.
0.6
100HP Motor Replaced With 75HP
Motor & New Energy Efficient
Pump Installed.
0.9
100HP Motor Replaced With 75HP
Motor & New Energy Efficient
Pump Installed.
0.8
100HP Motor Replaced With 75HP
Motor & New Energy Efficient
Pump Installed.
0.7
40HP Motor Replaced With 20 HP
Motor & New Energy Efficient
Pump Installed.
Cont… In Terms of Savings
ENERGY CONSERVATION PROJECTS DURING 2014-2015
SR.
NO.
PROJECT
AREA
POWER CONSUMPTION (KW)
SAVING IN
SAVING IN
BEFORE
AFTER
MODIFICATION MODIFICATION
KWH (PER
ANNUM)
Rs.
MILLIONS
REMARKS
7
ALKALI WASHER
PULP MILL
CLEANING SHOWER
21
9
95040
0.7
40HP Motor Replaced With 15 HP Motor &
New Energy Efficient Pump Installed.
8
HYPO SUPPLY PUMP
PULP MILL
(AGRO)
6.5
3.5
23760
0.2
15HP Motor Replaced With 7.5 HP Motor &
New Energy Efficient Pump Installed.
9
HYPO SUPPLY PUMP
PULP MILL
(HARDWOOD)
7
3.5
27720
0.2
15HP Motor Replaced With 7.5 HP Motor &
New Energy Efficient Pump Installed.
285
221
506880
3.5
VFD Installed
11 VACUUM PUMP NO.1 PM # 3
138
104
269280
1.9
220HP Motor Replaced With 150 HP Motor
& New Energy Efficient Pump Installed.
12 VACUUM PUMP NO.2 PM # 3
131
122
71280
0.5
220HP Motor Replaced With 180 HP Motor
& New Energy Efficient Pump Installed.
10 FEED WATER PUMP
POWER
HOUSE
Achievement:- In Terms of Savings
ENERGY CONSERVATION PROJECTS DURING 2015-16
SAVING
IN
SAVING
KWH
BEFORE
AFTER
RS.millions
(PER
MODIFICATION MODIFICATION
ANNUM)
POWER CONSUMPTION (KW)
Sr.
No.
PROJECT
Area
REMARKS
50HP/960RPM MOTOR REPLACED
WITH 40HP/960RPM MOTOR
50HP/960RPM MOTOR REPLACED
WITH 30HP/960RPM MOTOR
1 H2 TOWER AGT.
PULPMILL
21.0
16.0
39600
0.28
2 H1 TOWER AGT.
PULPMILL
19.0
12.0
55440
0.39
3 WASH WATER PUMP
PULPMILL
84.0
68.0
126720
0.89
VFD INSTALLED
4 WHITE LIQUOR PUMP CD PULPMILL
38.0
20.0
142560
1.00
VFD INSTALLED
5 CBD BLACK LIQ. PUMP
PULPMILL
74.0
54.0
158400
1.11
VFD INSTALLED
6 MC PUMP
PULPMILL
41.0
37.0
31680
0.22
VFD INSTALLED
7 MC PUMP
PULPMILL
38.0
25.0
102960
0.72
VFD INSTALLED
8 DILUTION PUMP
PM#3
38.0
19.0
150480
1.05
9 CHEST NO.40 PUMP
PM#3
18.5
13.0
43560
0.30
10 CHEST NO.38 PUMP
PM#3
12.0
8.0
31680
0.22
11 CHEST NO.39 PUMP
PM#3
11.5
10.0
11880
0.08
12 BOOSTER PUMP
PM#3
86.0
31.0
435600
3.05
75HP/1440RPM MOTOR REPLACED
WITH 50HP/960RPM MOTOR
30HP/1440RPM MOTOR REPLACED
WITH 20HP/1440RPM MOTOR
25HP/1440RPM MOTOR REPLACED
WITH 15HP/1440RPM MOTOR
25HP/1440RPM MOTOR REPLACED
WITH 20HP/1440RPM MOTOR
VFD INSTALLED
Cont… In Terms of Savings
ENERGY CONSERVATION PROJECTS DURING 2015-16
SAVING
IN
SAVING
KWH
BEFORE
AFTER
RS.millions
(PER
MODIFICATION MODIFICATION
ANNUM)
POWER CONSUMPTION (KW)
Sr.
No.
PROJECT
Area
REMARKS
13 BOOSTER PUMP
PM#3
26.0
15.0
87120
0.61
VFD INSTALLED
14 30M3 PUMP
PM#3
22.0
11.1
86328
0.60
VFD INSTALLED
15 15M3 PUMP
PM#3
18.5
8.8
76824
0.54
VFD INSTALLED
16 SCC PUMP
PM#3
50.0
32.0
142560
1.00
VFD INSTALLED
17 TCC Pump
PM#4
82.8
77.6
40988
0.29
IMPELLER TRIMMED
18 F/CHEST PUMP (CLEAR) # 60 PM#4
49.5
44.0
43180
0.30
VFD INSTALLED
29.7
13.0
132492
0.93
VFD INSTALLED
20.1
8.0
96037
0.67
VFD INSTALLED
18.4
12.0
50694
0.35
VFD INSTALLED
H/W REFINED (BLEND)
PM#4
CHEST- PUMP
S/Wood REFINED CHESTPM#4
20
PUMP
HARDWOOD SPARE CHEST PM#4
21
PUMP
19
22 DEFLAKER CHEST PUMP
PM#4
23.0
9.0
110888
0.78
VFD INSTALLED
23 CVACUUM SEAL PIT PUMP
PM#4
16.0
11.0
39600
0.28
VFD INSTALLED
3.05
EXISTING AGITATOR REPLACED WITH
NEW TECHNOLOGY AGITATOR OF NORD
MAKE
PURCHASED H/W HOLDING
PM#4
24
CHEST AGITATORT (2KV)
68.7
13.8
435149
Cont… In Terms of Savings
ENERGY CONSERVATION PROJECTS DURING 2015-16
POWER CONSUMPTION (KW)
Sr.
No.
PROJECT
Area
SAVING
IN
SAVING
REMARKS
KWH RS.millions
BEFORE
AFTER
(PER
MODIFICATION MODIFICATION
ANNUM)
25 COAL CRUSHER (BOILER # 4) POWER HOUSE
32
26
47520
0.33
75HP 1440RPM MOTOR REPLACED WITH
50HP 960RPM
26 CEP PUMP
POWER HOUSE
7.4
4.8
20592
0.14
VFD INSTALLED
27 FD FAN BOILER NO.3
POWER HOUSE
87
55
253440
1.77
VFD INSTALLED
28 SCFT PUMP
CRP
17
4
102960
0.72
VFD INSTALLED
29 PLFT PUMP
CRP
11
8.7
18216
0.13
VFD INSTALLED
30 AMT TANK TRANSFER PUMP CRP
7
2.3
37224
0.26
VFD INSTALLED
31 PCFT PUMP
CRP
5
1.2
30096
0.21
VFD INSTALLED
32 COOLING TOWER PUMP
CRP
95
77
142560
1
VFD INSTALLED
CRP
6
4
15840
0.11
VFD INSTALLED
CRP
6
4
15840
0.11
VFD INSTALLED
GREEN LIQUOR TRANSFER
PP.
WHITE LIQUOR TRANSFER
34
PP.
33
PROJECTS WITH “NO INVESTMENT “
 PAPER MACHINE-04 PRIMARY CENTICLEANER 11 KV
DRIVEN MOTOR PUMP IMPELLER TRIMMED FOR FY 2014-15 .
Power Consumption Before Pump Impeller Trim = 709 Kw
Power Consumption After Pump Impeller Trim = 518 Kw
Power Consumption Saving Per Hours = 191 Kw
Power Consumption Saving 15,12,720 Kwh/Annum.
PROJECTS WITH “NO INVESTMENT “
 PAPER MACHINE-04 TERITARY CENTICLEANER PUMP
IMPELLER TRIMMED FOR FY 2015-16.
Power Consumption Before Pump Impeller Trim = 83 Kw
Power Consumption After Pump Impeller Trim = 78 Kw
Power Consumption Saving Per Hours = 5 Kw
Power Consumption Saving 40988 Kwh/Annum.
In Terms of Kwh/MT of Finished Production
Description
Specific Electrical
Energy Consumption
2013-14 2014-15 2015-16 2016-17
Kwh/MT of Finished
Production
1217
1240
1217
1223
1198
1223
1198
1220
1200
1154
1180
1160
1140
1120
1100
Kwh/MT of
Finished
Production
2013-14
2014-15
2015-16
2016-17
1154
In Terms of Mtoe /Finished Production
Description
Specific Energy
Consumption
2013-14 2014-15 2015-16 2016-17
Sec(Mtoe)
0.505
0.450
0.377
Specific Energy Consumption Sec(Mtoe)
0.6
0.505
0.450
0.377
0.5
0.4
0.270
0.3
0.2
0.1
0
2013-14
2014-15
2015-16
2016-17
0.270
INNOVATIVE PROJECTS:
USES OF BIOGAS AS A FUEL IN BOILER’S FROM UPFLOW
ANAROBIC SLUDGE BLANKET.
CONVERSION FROM RICE STRAW TO ETHANOL BY
FERMENTATION (PLANT UNDER ERECTION STAGE).
BIOCLEANER TECHNOLOGY:
 BIOCLEANER TECHNOLOGY:
The company has also entered into a tripartite agreement with
Department of Biotechnology, Himachal Pradesh University, Shimla
and M/s Bio Cleaner, USA for implementing IMBR (Immobilized
Microbial Bioreactor) technology for waste handling in various sectors
including Pulp & Paper, Sludge Disposal, Sewage Treatment etc.
Implementation of IMBR technology in pulp & Paper industry for
liquefaction of waste activated sludge for addressing the problem of
secondary sludge disposal with minimal power consumption and
demonstration of IMBR technology for Sewage treatment at
Municipal Corporation Shimla, are the key achievements of the
Company in this area of Environmental Research.

 BIOCLEANER TECHNOLOGY:

Team Work in ENCON:
•Steering Committee
• MD & Senior Leadership
•Guiding Panel Champions
• Technical Head
• Process Head
•Area Improvement Team
• Department Heads ,
Executives and service
department members
KAIZEN SCHEME:
Kuantum Papers has achieved benefits of rupees worth 42.7 million
INR through Kaizen scheme.
 Kaizen Committee has been constituted who review and implement
the Kaizens submitted by the employees.
28 teams across 8 sections in the Paper mill has been constituted
No of Kaizen Submitted is 234 in 2016-17

UTILIZATION OF MILL WASTE:
Kuantum Papers Limited also uses the mill
waste as a fuel in boilers for environment
cleaning.
WOOD CHIPS DUST.
PITH.
STRAW DUST.
Utilization of ETP sludge for board making.
Boiler Fly ash for bricks making.
Renewable Energy:
 CELLULOSIC ETHANOL PROJECT:
Company has also been granted a prestigious project from BIRAC,
Department of Bio-Technology, GOI titled, “Cellulosic ethanol pilot plant
for rice straw management” worth Rs. 18.32 Crores for demonstration of
patented technology acquired by the company, to address the issue of
paddy straw burning in open fields by the farmers leading to air
pollution. This project is currently in the advanced stage of
implementation and successful demonstration of this technology will
provide a viable solution for various stakeholders including Punjab
Pollution Control Board and Govt. of Punjab, besides contributing
significantly for implementation of Ethanol Blending Programme of
Govt. of India. According to an estimate, after successful demonstration
of the technology currently implemented by Kuantum Papers Ltd,
 can alone meet the demand of 10% ethanol blending requirement
Punjab
of entire country by using paddy straw which is burnt in the open fields
by the farmers in the absence of any viable technology.
Renewable Energy:
 CELLULOSIC ETHANOL PROJECT:
Renewable Energy:
 BIOMETHANATION OF WET WASHING EFFLUENT:
Wet washing effluent generated during wet cleaning of agro-residues is
treated in the biomethanation plant based on Upflow Anaerobic
Sludge Blanket ( UASB Technology) for reduction in pollution load
with biogas as a byproduct. The biogas generated in the UASB reactor
is used as fuel in the FBC Boiler.

Renewable Energy:
 BIOMETHANATION OF WET WASHING EFFLUENT:

Renewable Energy:
Boimethane Generation
Description
Units
April -17
May -17
June- 17
July -17
Biomethane generation
M³
73039
80099
58879
73566
LP Steam consumption in
Biogas Plant
MT
51
31
25
20
Rice husk saving
equivalent to methane gas
MT
78.14
85.69
62.99
78.70
Rs.(Lacs)
23.60
27.70
20.19
26.06
Rice husk saving
Thanks...
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