Best Energy Practices Implementation in Seshasayee Paper Knowledge Exchange Platform Workshop Bureau of Energy Efficiency & Institute of Industrial Productivity New Delhi 26 th Feb 2015 Dr T.G.Sundara Raman,SPB 1
Paper Industry- Emission Mitigation Strategies • Improving Energy efficiency of the Process • Energy Conservation • Cleaner fuels Usage for energy generation • Efficient high pressure cogeneration with increased cycle efficiency • In house Biomass generated by the process [BLS,wood dust, bagasse pith etc.] usage • Conversion of waste (solid, liquid /gaseous) to energy 2
Innovative Energy Efficient Initiatives 3
SPB: CPP Unit Process Flow PSH SSH ~G Spray STG 12 BOILER E1 ata 5 ata To Process ECO 0.1 ata E2 To Process & Deaerator OUT C CT IN LP Steam CW Deaerator FST SJE/GSC Steam 4
Power Enhancement Concept- First of its kind • Automation Control Scheme Implemented & in successful operation ensuring high degree of exhaust condensing steam wetness related to increased Power generation; alongside maintaining high degree of condenser vacuum in 21 MW Extraction Condensing STG of Captive Power Plant. 5
21 MW STG Exhaust Steam Dryness Fraction DCS Snap shot 6
21 MW CPP-Power Enhancement Scheme – Summary Section Parameter Impact Result Outcome Condenser CW Flow CW outlet temp. Lowered CW exit Minor increase – Cooling increase drops increasing temperature; in condenser Water LMTD & possible Heat transfer vacuum Circuit lowering of exhaust coefficient Steam temp. increases due to increased CW velocity Exhaust Highly Steam Enthalpy Enhanced Power Power increase Steam desirable differential increases Generation through : 0.3 to 0.4 MW wetness [restricted increased cycle [inclusive of to < 15%] efficiency above factor] Condenser Advantage- Ensures higher Power - Vacuum- ous steam energy enhancement High exchange through marginal higher DP available Generator PF >0.95 Generator efficiency Marginal increase in 0.05 -0.1 MW desirable increases Power generation High Generator efficiency Increase in Power - 7 operating increases generation load
Innovative Project – High Pressure AFBC Boiler ISPB : D-E-B / 900 Heat Release Computation Total DRUM d / dt Energy PRESSURE Flow Heat Release Heat Release is used as measured variable for master fuel control algorithm Advantages of Heat Release: • Independent of Fuel measurement system • Totalizes fuel from all sources internally 8 • Monitors Change in Fuel quality
Advances in Instrumentation & Control Automation • Integrated Direct Energy Balance Automation Concept in HP Cogen Plant (First of its kind ) • Power consumption reduction : 0.15 MW • Boiler Steam Pressure Swings minimized ensuring higher power output. • Load Sharing Control Scheme with both Cogen units • With VFD - ID & PA Fans in place, Power savings are doubled 9
Waste to Energy Conversion Boiler #10- LOI redn. in flyash P.A. pressure reduced from 1400 to 1200 mmWC • LOI in Flyash reduced from 12% to 6% • Combustion η increased by : 0.5 to 0.6 % • Coal saving : 60 to 70 te/month • GHGE reduction:900 to 1100 tCO2/yr • Easy disposal of flyash to Cement mill 10
Optimization of Operation of Coal fired Cogeneration Battery • For deriving maximum mileage from 2 the high cycle efficiency of CPP , it had been decided to run the 3 MW STG sparingly and limit steam 1.43 1.6 Spec.Coal Consn.[t/t] 1.31 generation to the extent practicable in 1.14 the low pressure coal fired boilers. 1.2 The shortfall in power requirement had been made up by grid power import. 0.8 • The above scheme coupled with the 0.4 high efficient operation of CPP unit, avoidance of HP steam through PRDS ( 105 bar) and implementation 0 of innovative Energy Management schemes had resulted in significant 2011-12 2012-13 2013-14 specific coal consumption reduction . 11
Innovative Low Carbon Schemes 12
Steam & Power Optimisation with 2 HP Cogen online BLR#10 VHP BLR#11 HP 16 MW 21 MW EBP DEC P2 P1 E1 E1 E2 E2 LP LP MP 13
Innovation related to LCE Maximizing Green Power generation in Recovery Cogeneration Unit through: • Minimal/No extraction & maximizing Exhaust LP flow in 16 MW STG • Maximizing steam inlet temperature through operating the Recovery Boiler at high SOT & effecting reduction in steam temperature loss through highly effective advanced state of the art insulation of MSL on-line 14
Waste to Power Advanced Boiler Main steam pipeline reinsulation- online ------------------------------------------------------------------------------ Replacing existing insulation with fresh insulation mattress of higher thk [210mm] & density [140kg/m3]- with new cladding pin design Steam temperature drop redn. from 10/12 ° C to 5/6 ° C. Radn & convecn heat loss redn. Enthalpy gain in 16MW STG: 3kcal/kg Addl. Power genern : 0.3 MW GHGE Reduction : 2400 tCO2/ yr 15
16 MW STG : Energy Management Maximizing E2 steam with E1 minimal- E1[MP]steam redn:From 8TPH to <1TPH • Power gen. increase …….…. : 0.4 MW • Addl. power gen. through increase in flow of E2 ........... : 0.05 MW • Addl Green power gen……. : 0.45 MW • REC ……………… : 300 units/month • GHGE reduction ……..: 1800 tCO2/yr 16
Recovery Cogen - Green Energy Management # Increased BLS firing to over 700 TPD # Optimization of Combustion air flow • Increased HP Steam gen. …..………: > 90 TPH • Increased Green power gen. …..: 10.5 -11 MW • Green steam to process ……..... : 33 to 36 TPH • GHGE reduction increase: 20,000-25,000 tCO2/yr • REC ………………… : Over 6000 units /month 17
Green Power Generation from 16 MW STG integrated to Recovery Boiler – since inception 12 Green Power [MW] 9.8 10 9.3 9.05 8.3 7.9 8 6.9 6.3 6 4 2 0 2008- 2009- 2010- 2011- 2012- 2013- Apr- 09 10 11 12 13 14 Dec 18 2014 18
Green Steam to Process 40 36 Steam - tph 35 30 29 30 25 Jan-Dec 12 Jan-Dec'13 Jan'14 -Dec '14 Steam to Process [tph] 19 19
Other Innovative Energy Management Schemes 20
Innovative Project Power Management - BFP Energy Efficient Pumps – Coal fired & Recovery Boilers Daily Steam Efficiency Efficiency Net Power Power Boiler Rate (Energy (Standard Savings% Savings TPH Efficient)% oper. )% in Units 10 85 70 47 50 5000 11 90 70 50 40 3000 21
Advanced Energy Conservation Scheme BFP for H.P. Steam Generator DP across EFBFP Control valves – Boiler 10 Efficiency [%] of BFP in Operation LargeBFP EFBFP CV original CV LowDP 80 40 DP across BFP CV [bar] BFP Efficiency [%] 70 30 60 20 50 10 40 0 70 84 98 112 126 140 70 82 94 106 117 Feed Water Flow to Boiler 10 [ TPH] Feed Water Flow to Boiler 10 [ TPH] Energy Saving : 1000 units/day 22
CPU+ HRU - Integrated Water & Energy Management - Boilers . Process Condensate : 90°C to 35°C DM Water Preheating : from 32°C Heat Recovery : 4 MWt To Deaerators FWT Hot Polished MB ACF PHEs Fluid Condensate Filter Process Hot / Condensate Tank ST 23
Total SEC Reduction – Last 3 Years SEC [GJ/te product] 24
PAT-Specific Energy Consumption Reduction Spec.Energy Consumption [MTOE/t product] 0.9 0.827 0.767 0.8 0.681 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 2011-12 2012-13 2013-14 25
GHG Emission Reduction [GtoG] 3.5 3.11 Spec.CO2 Emission [tCO2/t product] 3 2.73 2.53 2.5 2 1.5 1 0.5 0 2011-12 2012-13 2013-14 26
Non Energy Benefits - New Concept [ACEEE] • SPM in Stack gas : < 50 mg/Nm3 • Water conservation through CPU - PHE in CPP • Nansulate coating in Dryer section – Scanner • Water conservation through lowered Dryness Fraction in 21 MW STG condensation steam exhaust 27
CSR -Social Promotion of GreenCo in SPB • Treated RO water for Drinking purposes • Waste Water for Irrigation -Cane • Green Initiatives Awareness for School students – Formation of Green Club in SPB High school • Encouraging Engng College students to do Industrial projects related to Green Initiatives 28
Initiated & On-Going Green Initiatives • Tree Farming – High Carbon Sequestration at Source • Landscape – Greening • Solar Heating system for Hot water for Canteen • Green Initiative – Solar Lightpipe in Finishing House of Paper Machine • In-Plant Training related to GreenCo Initiatives 29
Recommend
More recommend
