best practices adopted by harihar polyfibers, grasim industries
TRANSCRIPT
Effective Utilization of Biomass to reduce Carbon Footprint
Case Study
Contents
Unit Profile Pulping Process Background Problem Statement Energy Efficiency Improvement Approach Root Cause Analysis Improvement Actions Benefits Sustainability Measures Way forward
ABG – Pulp & Fibre Units
VSF Plants
Nagda (MP)Harihar (Kar)Vilayat (Guj) PKharach (Guj)
IBR (Indonesia)
Harihar (Kar)
AV Cell , A V Nackawic, AV TB,
Canada
Baroda + 8 RO / BO
Jakarta
Bangkok
IstanbulCharlotte
Grasim (India) 4
TRC (Thailand) 1
BJFC (China) 1
IBR (Indonesia) 1
Pulp Plants
Grasim (India) 1
AV Cell, AV Nackc., AV TB (Canada)
3
Domsjo, Sweden 1
BLPP (Laos) 1
Marketing Offices
India Turkey
Thailand USA
Indonesia
BJFC (China)
BLPP (Lao)
TRC (Thailand)
VSF Plants
Pulp Plants
Marketing Offices
Domsjo, Sweden
Pulp Plant
Established : 1972 Raw Material : Eucalyptus
Process : Prehydrolysis Sulphate Capacity : 74,400 TPA
Product : Rayon Grade Pulp
Wood Operation Product
Wood to Pulp
Cellulose40%
HemiCellulose
30%
Lignin 25%Extractives
5%
C
O
O
K
I
N
G
AlphaCellulose
Waste PHLiquor
BlackLiquor
Cooked, Washed &Bleached
Anaerobic Digestion
Burnt inRecovery
Boiler
R G Pulp
Bio gas
Steam &
Power
Background
Biogas Plant Installed under BOOT scheme by M/s MGPL in 1996
Biogas plant handed over to Grasim in Dec 2013
Limitations of Biogas Plant as on Nov-2013 at the time of
takeover by Grasim
• Full capacity of the plant not utilised
• Maximum Methane Content in biogas – 60 %
• FO replacement in Lime Kiln – 34%
Problem Statement
Full potential to generate biogas, to replace FO and in turn reduce carbon
foot print not achieved
To improve Biogas plant efficiency
• Team Formation
• Training
• Data Collection
• Discussion with Experts
Approach
Root Cause Analysis
• No skilled supervisory staff
• Inadequate skill level of the operatorsMen
• Lime mixing with PH liquor was not proper
• Improper movement of Gas Holder due to damaged wheels thereby escape of gas from the holder
Machine
• Use of quick lime resulting in feed pH variation
• Use of crude SF oil as surfactant - foam generationMaterial
Method
• Non availability of standard operating procedures
• COD loading not uniform to all the three reactors
• Gas supply pressure to LK -2300 mmWC
• Dilution by UB backwater from pulp mill
• Adhoc addition of micronutrients
Root Cause Analysis
Men
Decided to maintain all the parameters withoutany changes and monitored the results for aweek.
Redeployment of suitable workforce withexclusive responsibility
Shift-wise monitoring of plant operatingparameters by staff.
Enhanced Competency of workers & officers byadequate training , assessment & re-training.
Actions Taken
Machine
Lime mixing tank capacity increased from 4 m3
to 10 m3
Connecting line size increased from 6ӯ to 8үto ensure proper gravity flow to clarifier.
Agitator Gear box replaced with higher capacityfor effective mixing.
Introduced baffles inside tank for better mixing Corroded channels of the gas holder replaced &
smooth movement of wheels ensured.
Actions Taken
Material
Replaced quick lime with hydrated lime tominimize feed pH variation.
Replaced crude SF oil with refined SF oil assurfactant for controlling foaming tendencyeffectively.
Actions Taken
Method
Developed Department procedure, plant start-up &stoppage procedure.
Standard method developed for uniform COD loading tothe reactors based on the VFA and alkalinity values ofthe reactor effluent.
Developed method to maintain higher gas pressure i.e.around 3000 mmWc.
Usage of unbleached backwater stopped and moreacclimatized reactor effluent recycle was increased fordilution
Usage of micronutrients viz. ammonium molybdate,nickel chloride and ferric chloride was controlled to dosein all shifts.
Actions Taken
Method
Developed standard methods and schedule for the reactorgutter cleaning & effluent overflow line cleaning to preventabrupt stoppage of the plant.
Developed procedure for regulating reactor effluent recycleto avoid substrate inhibition
Developed SOP to analyze all the vital parameters. Optimizedanalysis frequency in order to take immediate action in casethere is any upset in the reactor performance.
Online sensors provided to measure critical parameters likepH and temperature, for taking timely corrective action.
Actions Taken
Actions Taken
Dual fuel burner installed to get Compact Medium Length
Flame for efficient utilization of both fuels
Benefits - Tangible
Particulars Unit
Before (during MGPL
period)
After (during Grasim
period)
Remarks
FY13
FY14
(Apr13-
Nov 13)
FY14
(Dec13-
Mar14)
FY15
Volume of PH
Liquor treatedm3/d 400 540 560 600
23%
increase
Volume of Biogas
generatedNm3/d 13790 19190 20290 23360
32%
increase
Methane content % 55 60 63 6511%
increase
FO Replaced % 24 34 40 5157%
increase
Financial GainRs.
Lac p.a.207 161 356 779
208%
increase
59
.28
49
.52
42
.84
32
.03
35
.89
29
.32
29
.59
29
.34
30
.22
28
.18
28
.37
6.2
5
15
.94
23
.61
33
.30
29
.36
35
.75
35
.55
35
.84
34
.55
36
.98
36
.80
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
FY 12 FY 13 FY 14 FY 15 Budget FY 16 UTD FY 16 Apr'15 May'15 June'15 July'15 Aug'15 (Upto7th)
Bet
ter
Biogas replacement Furnace OIl
Lime Kiln - FO replacement in kg/t
Benefits – Intangible
Reduction in carbon emissions equivalent to ~ 1.5 Lac
tons CO2e per year.
Reduced COD load on ETP thereby increasing the ETP
efficiency.
Use of green energy replacing the fossil fuel helped to
improve industry’s image.
Use of renewable energy and conversion of waste into
wealth resulted in “Sustainable Development” of the
pulping operation
Reduced cost of production due to reduction in FO
consumption
Sustainability Measures
Compare operation of biogas plant with best run biogas plant to
standardize the operation further.
To overcome sudden jerks in performance regular addition of cow
dung and ETP biomass has been started.
Started plotting the control chart for all vital parameters such as
VFA, alkalinity & pH.
Weekly monitoring of biomass quality from port samples of all the
reactors.
SOP developed to take quick decision on PH liquor volume
increase or decrease to control COD loading.
Online methane analyzer installed for better control of reactor
parameters.
Housekeeping in the plant given utmost importance to improve the
productivity of the plant.
Way forward
To further increase methane content by using super
clones of microorganisms – work is in progress.
To enrich methane content in biogas by sequestering
CO2 – Project under formulation.
Biogas is being supplied to canteen to replace 75%
LPG. It is planned to replace 100% LPG in next three
months.
Thank You