Seshasayee Paper Knowledge Exchange Platform Workshop Bureau of - - PowerPoint PPT Presentation

1

Best Energy Practices Implementation in Seshasayee Paper

Knowledge Exchange Platform Workshop Bureau of Energy Efficiency & Institute of Industrial Productivity New Delhi 26th Feb 2015

Dr T.G.Sundara Raman,SPB

2

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

3

Innovative Energy Efficient Initiatives

4

SPB: CPP Unit Process Flow

E2

C

BOILER

PSH SSH ECO E1

To Process To Process & Deaerator

CT

OUT IN

CW

0.1 ata 12 ata 5 ata

Steam

SJE/GSC

FST Spray

Deaerator

LP Steam

STG ~G

5

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

• f condenser vacuum in 21 MW Extraction

Condensing STG of Captive Power Plant.

6

21 MW STG Exhaust Steam Dryness Fraction DCS Snap shot

7

21 MW CPP-Power Enhancement Scheme–Summary

Section Parameter Impact Result Outcome

Condenser –Cooling Water Circuit CW Flow increase CW outlet temp. drops increasing LMTD & possible lowering of exhaust Steam temp. Lowered CW exit temperature; Heat transfer coefficient increases due to increased CW velocity Minor increase in condenser vacuum Exhaust Steam wetness Highly desirable [restricted to < 15%] Steam Enthalpy differential increases Enhanced Power Generation through increased cycle efficiency Power increase : 0.3 to 0.4 MW [inclusive of above factor] Condenser Vacuum- High Advantage-

• us

Ensures higher steam energy exchange through higher DP available Power enhancement marginal

• Generator

PF >0.95 desirable Generator efficiency increases Marginal increase in Power generation 0.05 -0.1 MW High

• perating

load Generator efficiency increases Increase in Power generation

8

Total Energy Flow Heat Release

ISPB : D-E-B / 900 Heat Release Computation

DRUM PRESSURE

Heat Release is used as measured variable for master fuel control algorithm

d /dt



Advantages of Heat Release:

• Independent of Fuel measurement system
• Totalizes fuel from all sources internally
• Monitors Change in Fuel quality

Innovative Project –High Pressure AFBC Boiler

9

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

10

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

Waste to Energy Conversion

11

Optimization of Operation of Coal fired Cogeneration Battery

• For deriving maximum mileage from

the high cycle efficiency of CPP , it had been decided to run the 3 MW STG sparingly and limit steam generation to the extent practicable in the low pressure coal fired boilers. The shortfall in power requirement had been made up by grid power import.

• The above scheme coupled with the

high efficient operation of CPP unit, avoidance of HP steam through PRDS ( 105 bar) and implementation

• f innovative Energy Management

schemes had resulted in significant specific coal consumption reduction . 1.43 1.31 1.14 0.4 0.8 1.2 1.6 2 2011-12 2012-13 2013-14

Spec.Coal Consn.[t/t]

12

Innovative Low Carbon Schemes

13

E2 E1 E1 E2 BLR#10 VHP BLR#11 HP P2 P1 21 MW

DEC

16 MW EBP

LP LP MP

Steam & Power Optimisation with 2 HP Cogen online

14

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
• perating 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

15

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

Waste to Power

16

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 MW STG : Energy Management Maximizing E2 steam with E1 minimal-

17

# 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

Recovery Cogen - Green Energy Management

18

18

Green Power Generation from 16 MW STG integrated to Recovery Boiler –since inception

6.3 6.9 7.9 8.3

9.05

9.3 9.8

2 4 6 8 10 12 2008- 09 2009- 10 2010- 11 2011- 12 2012- 13 2013- 14 Apr- Dec 2014 Green Power [MW]

19

19

Green Steam to Process

29 30 36

25 30 35 40 Jan-Dec 12 Jan-Dec'13 Jan'14 -Dec '14 Steam to Process [tph] Steam - tph

20

Other Innovative Energy Management

Schemes

21

Boiler Steam Rate TPH Efficiency (Energy Efficient)% Efficiency (Standard

• per. )%

Net Power Savings% Daily Power Savings in Units

10 85 70 47 50 5000 11 90 70 50 40 3000

Energy Efficient Pumps – Coal fired & Recovery Boilers

Innovative Project Power Management - BFP

22

Advanced Energy Conservation Scheme BFP for H.P. Steam Generator

Efficiency [%] of BFP in Operation

40 50 60 70 80 70 84 98 112 126 140 LargeBFP EFBFP Feed Water Flow to Boiler 10 [ TPH] BFP Efficiency [%]

DP across EFBFP Control valves –Boiler 10

10 20 30 40 70 82 94 106 117 CV original CV LowDP Feed Water Flow to Boiler 10 [ TPH] DP across BFP CV [bar]

Energy Saving : 1000 units/day

23

.

ACF

MB ST FWT

Process Hot / Condensate Tank Filter Polished Condensate To Deaerators

PHEs

Hot Fluid Process Condensate : 90°C to 35°C DM Water Preheating : from 32°C Heat Recovery : 4 MWt

CPU+ HRU - Integrated Water & Energy Management - Boilers

24

Total SEC Reduction – Last 3 Years

SEC [GJ/te product]

25 0.827 0.767 0.681 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 2011-12 2012-13 2013-14

PAT-Specific Energy Consumption Reduction

Spec.Energy Consumption [MTOE/t product]

26

2.53 2.73 3.11

0.5 1 1.5 2 2.5 3 3.5 2011-12 2012-13 2013-14

GHG Emission Reduction [GtoG]

Spec.CO2 Emission [tCO2/t product]

27

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

28

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

29

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

30

Innovative Energy Conservation Schemes

Implemented-Summary

Unit Activi ivity ty SPB to Benefici ficiari aries Cogenera eratio tion n Power r Plants ts Direct ct Energy gy Balance nce-40 400 for margin inal l incre rease ase in Power r generati ration

• n

Metso so Automa

• mati

tion

• n

Captive ive Power r Plant nt Power r incre rease ase through

• ugh Exhaust

ust steam am Dryness ess fract ction

• n mainten

tenance nce through contro trol l automa mati tion scheme me All Thermal mal & Indust stri rial al Power r Plants ts HP Cogenera eratio tion n Battery tery MP to LP steam m switch ch for maximizi mizing g Power r generatio ation-ST STG All Back pressure sure Cogenera eratio tion n units ts HRU HRU -CPU Heat recovery very & DM water er conserva ervatio tion Proce cess ss Industries stries

Nansul ulate ate - Dryin

ing g cylin linder der ends ds & Scan anner ner

Steam am reduction ction ; scanner nner made

• perationa

ational Nanotech tech. . USA Energy gy effi ficie cient nt BFP integra rated ted with CV Station tion Power r consump umptio tion n reduct ction

• n

All Boiler r Feed water er Pumps

Advanc anced ed thermal al insul ulati ation

• n of Main steam

am pipel eline ne

Increased reased Green en Power r generati ration

• n

All STGs s world over

31

Clean ,Green & Strong

Continuously strives for improving the 3 Es-

• Energy Conservation
• Environment Control &
• Emission Reduction

On a Sustained and Continuous basis