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 - SailaKhurd, 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 Boiler

21 TPH 67 Kg/cm2 Grid S/S Supply at 66 KV

10.5 MVA

Pulp Mill Details

Agro Section Hardwood Section

Agro Street 160 TPD Hard Wood 60 TPD

Paper Machines Other Sections

Paper Machine-01 25 TPD Effulent Tratment Plant 20000m3/day

Paper Machine-02 30 TPDChemical Recovery Plant

200 TPD

Paper Machine-03 100 TPD Lime Kiln Plant 40 TPD

Paper Machine-04 250 TPD Fluidized Bed Reactor 85 TPD

Plant Equipment Details:-

Achievement:- In Terms of Savings

ENERGY CONSERVATION PROJECTS DURING 2014-2015

SR.

NOPROJECT AREA

POWER CONSUMPTION (KW) SAVING IN SAVING IN

REMARKSBEFORE

MODIFICATION

AFTER

MODIFICATION

KWH (PER

ANNUM)

Rs.

MILLIONS

1 PCC PUMP PM # 4 709 518 1512720 10.6 Pump Impeller Trimmed.

2BSW#0 VAT DILUTION

PUMP

PULP

MILL56.2 45 88704 0.6

100HP Motor Replaced With 75HP

Motor & New Energy Efficient Pump Installed.

3BSW#1 VAT DILUTION

PUMP

PULP

MILL54.4 44 82368 0.6

100HP Motor Replaced With 75HP

Motor & New Energy Efficient Pump Installed.

4BSW#2 VAT DILUTION

PUMP

PULP

MILL52.5 37 122760 0.9

100HP Motor Replaced With 75HP

Motor & New Energy Efficient Pump Installed.

5BSW#3 VAT DILUTION

PUMP

PULP

MILL52 37 118800 0.8

100HP Motor Replaced With 75HP

Motor & New Energy Efficient

Pump Installed.

6DECKER WASHER

CLEANING SHOWER

PULP

MILL21.9 10 94248 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

REMARKSBEFORE

MODIFICATION

AFTER

MODIFICATION

KWH (PER

ANNUM)

Rs.

MILLIONS

7ALKALI WASHER

CLEANING SHOWERPULP MILL 21 9 95040 0.7

40HP Motor Replaced With 15 HP Motor &

New Energy Efficient Pump Installed.

8HYPO SUPPLY PUMP

(AGRO)PULP MILL 6.5 3.5 23760 0.2

15HP Motor Replaced With 7.5 HP Motor &

New Energy Efficient Pump Installed.

9HYPO SUPPLY PUMP

(HARDWOOD)PULP MILL 7 3.5 27720 0.2

15HP Motor Replaced With 7.5 HP Motor &

New Energy Efficient Pump Installed.

10 FEED WATER PUMPPOWER

HOUSE285 221 506880 3.5 VFD Installed

11 VACUUM PUMP NO.1 PM # 3 138 104 269280 1.9220HP Motor Replaced With 150 HP Motor

& New Energy Efficient Pump Installed.

12 VACUUM PUMP NO.2 PM # 3 131 122 71280 0.5220HP Motor Replaced With 180 HP Motor

& New Energy Efficient Pump Installed.

Achievement:- In Terms of Savings

ENERGY CONSERVATION PROJECTS DURING 2015-16

Sr.

No.PROJECT Area

POWER CONSUMPTION (KW)SAVING

INSAVING

RS.millionsREMARKS

BEFORE

MODIFICATION

AFTER

MODIFICATION

KWH

(PER

ANNUM)

1 H2 TOWER AGT. PULPMILL 21.0 16.0 39600 0.2850HP/960RPM MOTOR REPLACED

WITH 40HP/960RPM MOTOR

2 H1 TOWER AGT. PULPMILL 19.0 12.0 55440 0.3950HP/960RPM MOTOR REPLACED

WITH 30HP/960RPM MOTOR

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 1.0575HP/1440RPM MOTOR REPLACED

WITH 50HP/960RPM MOTOR

9 CHEST NO.40 PUMP PM#3 18.5 13.0 43560 0.3030HP/1440RPM MOTOR REPLACED

WITH 20HP/1440RPM MOTOR

10 CHEST NO.38 PUMP PM#3 12.0 8.0 31680 0.2225HP/1440RPM MOTOR REPLACED

WITH 15HP/1440RPM MOTOR

11 CHEST NO.39 PUMP PM#3 11.5 10.0 11880 0.0825HP/1440RPM MOTOR REPLACED

WITH 20HP/1440RPM MOTOR

12 BOOSTER PUMP PM#3 86.0 31.0 435600 3.05 VFD INSTALLED

Cont… In Terms of Savings ENERGY CONSERVATION PROJECTS DURING 2015-16

Sr.

No.PROJECT Area

POWER CONSUMPTION (KW)SAVING

INSAVING

RS.millionsREMARKS

BEFORE

MODIFICATION

AFTER

MODIFICATION

KWH

(PER

ANNUM)

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

19H/W REFINED (BLEND) CHEST- PUMP

PM#4 29.7 13.0 132492 0.93 VFD INSTALLED

20S/Wood REFINED CHEST-PUMP

PM#4 20.1 8.0 96037 0.67 VFD INSTALLED

21HARDWOOD SPARE CHEST -PUMP

PM#4 18.4 12.0 50694 0.35 VFD INSTALLED

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

24PURCHASED H/W HOLDING CHEST AGITATORT (2KV)

PM#4 68.7 13.8 435149 3.05EXISTING AGITATOR REPLACED WITH NEW TECHNOLOGY AGITATOR OF NORD MAKE

Cont… In Terms of Savings

ENERGY CONSERVATION PROJECTS DURING 2015-16

Sr.

No.PROJECT Area

POWER CONSUMPTION (KW)SAVING

INSAVING

RS.millionsREMARKS

BEFORE

MODIFICATION

AFTER

MODIFICATION

KWH

(PER

ANNUM)

25 COAL CRUSHER (BOILER # 4) POWER HOUSE 32 26 47520 0.3375HP 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

33GREEN LIQUOR TRANSFER PP.

CRP 6 4 15840 0.11 VFD INSTALLED

34WHITE LIQUOR TRANSFER PP.

CRP 6 4 15840 0.11 VFD INSTALLED

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.

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.

PROJECTS WITH “NO INVESTMENT “

In Terms of Kwh/MT of Finished Production

Description 2013-14 2014-15 2015-16 2016-17

Specific Electrical Energy Consumption

Kwh/MT of Finished Production

1217 1223 1198 1154

1100

1120

1140

1160

1180

1200

1220

1240

Kwh/MT of Finished

Production

2013-14 2014-15 2015-16 2016-17

12171223

1198

1154

In Terms of Mtoe /Finished Production

Description 2013-14 2014-15 2015-16 2016-17

Specific Energy

ConsumptionSec(Mtoe) 0.505 0.450 0.377 0.270

0

0.1

0.2

0.3

0.4

0.5

0.6

2013-14 2014-15 2015-16 2016-17

0.5050.450

0.377

0.270

Specific Energy Consumption Sec(Mtoe)

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,

Punjab can alone meet the demand of 10% ethanol blending requirement

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 savingequivalent to methane gas

MT 78.14 85.69 62.99 78.70

Rice husk saving Rs.(Lacs) 23.60 27.70 20.19 26.06

Thanks...