Date(s) - 21/08/2015
First Workshop on Best Practices in Energy Efficiency in Pulp & Paper Sector
The 1st Pulp and paper Sector workshop under Knowledge Exchange Platform (KEP) initiative was hosted by J.K. Paper Limited, at India Habitat Centre, New Delhi, for exchange of best practices in pulp and paper industries covered under the Perform Achieve and Trade (PAT) scheme. PAT is a flagship initiative of Bureau of Energy Efficiency (BEE), Government of India for promoting energy efficiency in large industries. In pulp and paper sector, 31 Designated Consumers are covered under the PAT scheme where energy savings of 0.816 million tonne of oil equivalent per year are expected to be achieved in the first cycle of PAT (2012-2015), which is around 12% of the total national energy saving targets of 6.686 million tonne of oil equivalent.
The Workshop was inaugurated by Dr. Ajay Mathur, Director General, Bureau of Energy Efficiency. In his inaugural address, he congratulated all the paper and pulp units in taking a large number of initiatives in the first cycle of PAT Scheme. He also thanked members of Technical Committee for consistently working towards resolving complicated issues like normalisation and commended the trust built in by PAT Cycle-1 between Government and industry. KEP established by BEE and Institute for Industrial Productivity (IIP) is one of the initiatives to strengthen this trust and in the process assist industry through various activities. He highlighted the importance of best practice sharing and mentioned that “I am sure that the KEP initiative will be able to deliver significant energy efficiency benefits for the industrial sector and will be able to build an atmosphere of collective learning and partnership with better performing DCs willing to share their knowledge with other DCs and workshops like these will help us achieve the goal of energy conservation.”
Welcome address was delivered by Mr. Sandeep Bhalla, General Manager, JK Paper Limited. In his address, he mentioned the importance of narrowing the energy performance gap of paper plants so as to reduce the energy intensity of the sector. This would require both sectoral and cross-sectoral collaboration and a dedicated platform like KEP can facilitate it within and across the paper industry.
In his special address, Mr. A S Mehta, President, JK Paper Limited said, “it is a great platform for knowledge sharing which will pave the way for adaptation of energy efficient practices in order to have a sustained growth with optimal utilization of our resources. At JK Paper we are pleased to organise this 1st workshop and promote peer to peer learning, outreach and rapid uptakes of best practices and new technologies with paper and pulp sector.”
Special addresses were also delivered by Mr. Simon Petrie, First Secretary, Low Carbon Growth, British High Commission, and Mr. K. K. Chakarvarti, Expert Consultant, BEE. In his address, Mr. Simon Petrie appreciated the support of the industry to the KEP initiative and Mr. Chakarvarti mentioned that the success of KEP depended on pro-active industry participation. Ms. Ritu Bharadwaj, Senior Program Manager, IIP India thanked the participants, speakers and in particular JK Paper limited for joining hands with KEP in organizing the event She mentioned that IIP was committed to work alongside BEE in taking this initiative forward and helping the industry achieve PAT objectives.
Dr. Ajay Mathur, Director General, Bureau of Energy Efficiency delivering the Inaugural address
The inaugural event was followed by two technical sessions and a panel discussion. The first technical session was Chaired by Mr. N K Agarwal, EVP (Works), JK Paper Limited, Unit- CPM. The discussion in the session focused on Monitoring and Verification (M&V) arrangements under PAT Scheme and Trading mechanism proposed for Energy Saving Certificates (ESCerts) particularly in reference to Renewable Energy Certificates. BEE presented the M&V provision under PAT for Pulp and paper sector, wherein the participants were informed about the current status as well as next steps proposed with regard to M&V. The presentation also covered the methodology to be adopted for second PAT cycle and the new plants proposed to be added in second cycle of PAT. The presentation on ESCerts focused on key aspects of ESCerts trading scheme and the progress made so far, which included status of ESCerts Exchange Regulations, roles and responsibilities of entities involved, formulation of business procedures for ESCerts exchange on Power Exchanges and up-gradation of PATNet Portal including M & V process.
Besides PAT, the session also focused on sharing of experience of the industry on implementation of innovative best practices. The industries that shared their experience included JK Paper Limited, Unit- JKPM, BILT Graphic Paper Products Limited,; ITC Limited, PSPD, Unit-Kovai; JK Paper Limited, Unit- CPM, Harihar Polyfibers, Grasim Industries. The session also had presentation on implementation of ISO 50001 by Ballarpur Industries Limited and.
Sharing and discussing their innovative best practices, the presentation by JK Paper Limited, Unit- JKPM focused on benefits achieved by recovering heat from bleach effluent, which has contributed to 69% reduction in steam consumption in pulp mill and higher steam generation in Recovery boiler. The presentation by BILT Graphic Paper Products Limited explained the Energy Efficiency Strategies adopted in Steam Condensate System (Waste Heat Recovery) Paper Machines, shutting of TG Set-7.5 MW and chiller optimization, which lead to monetary saving of Rs 150 Lac/Annum, Rs. 7.8 crore and Rs. 27.7 Lakhs, respectively. Explaining new approaches to energy efficiency, a presentation by GIZ described the strategies that can be adopted for steam optimization in Drying Cylinder of Paper machine, which lead to monetary saving of approximately Rs. 855,000/Year.
Mr. N K Agarwal with the panelists of the first technical session
The presentation by ITC Limited, PSPD, Unit – Kovai, explained the best practices adopted in the cogeneration plant by Installing 1 x 72t/h AFBC Boiler at 87kg/cm2 and 520 Deg C designed for F grade coal. This initiative led to reduction in heat rate of the cogeneration plant and energy cost reduction of Rs. 18 Cr per annum. The presentation also discussed the benefits reaped by installing a turbo blower (multi-stage blower) which reduced the water requirement by 97%. The presentation by JK Paper Limited, Unit-CPM highlighted the energy saving achieved by installation of VFD in root blower, power factor improvement from 0.82 to0.88, utilization of all coal fired boilers and liquor fired boiler CBD & IBD hot water in causticizing & pulp mill and steam saving in power generation by optimizing steam extraction in TG 3 &TG 4, which led to annual monetary saving of Rs. 2.54 Lakhs, Rs. 98.73 Lakhs, Rs. 39.71 Lakhs and Rs. 1.63 Cr, respectively. The presentation by Ballarpur Industries Limited described the journey towards implementation of Energy Management system, ISO 50001, which included the road map followed, challenges faced and benefits reaped. The last presentation in the Technical Session 1 covered the effective utilization of Biomass to reduce carbon footprint, which was presented by Harihar Polyfibers, Grasim Industries. It covered the root cause analysis and the action plan to enhance the utilization of Biomass in order to reduce the carbon foot print, leading to annual monetary saving of Rs. 779 Lakhs.
Mr. N K Agarwal with the panelists of the first technical session
The second technical session was focused on energy efficiency technologies available for pulp & paper sector. The session was chaired by Mr. K. Suresh, President, Harihar Polyfibers, which is unit of Grasim Industries. This session was planned in a manner that it brought together the technology providers and industry representatives with a view to promote interactions between the two stakeholder groups that can help in facilitating adoption of cleaner technologies. The session had presentations on technologies available for various process in pulp making viz. cross learning for steam systems by Forbes Marshall, energy efficiency in ETP of a Paper mill by Paques Environmental Technology India Pvt. Ltd, power plant optimization through analysis and testing by Solvina International AB, advanced control solutions for pulp mill by ABB India Limited, petroleum coke handling and firing in rotary lime kiln by Agro Pulping Machinery (P) Ltd and energy conservation in compressed air systems by Atlas Copco (India) Limited.
KEP is planning to launch an interactive website that can facilitate knowledge transfer and discussion between stakeholder groups related to different PAT sectors. A demo version of KEP website (knowledgeplatform.in) was also presented to the participants to get their feedback on different features to ensure that it met industry’s expectations and needs.
Mr. K Suresh with the panelists of second technical session
Technical sessions was followed by a panel discussion on future strategies to be adopted and need for promoting innovative, new and cutting edge technologies and cross-sectoral best practices. The panelists were the members of Sector Learning Group. The panelist briefly explained the key discussion points of the SLG meeting, which was held a day before the workshop (20th August, 2015) and concluded that KEP can play an important role in facilitating policy discussions around PAT, particularly, as it is moving in to the next cycle where the pulp & paper industry is expected to have new targets and more plants are expected to come under the ambit of PAT. Panelist also felt that KEP will be in a position to assist the industries to meet the new targets by bringing in international best practices and technologies and also promoting cross sectoral exchange of best practices, in particular, from thermal sector.
SLG members as the Panelists at the Panel discussion
The workshop had participation from over 100 eminent pulp & paper industry leaders, Industry Association, technology providers, distinguished speakers, energy managers and auditors, and senior industry professionals amongst many others.
Participants at the 1st Pulp & Paper Workshop under Knowledge Exchange Platform initiative
|INAUGURAL SESSION (9.00 AM- 9.45 AM)|
|Lighting of Lamp|
|Welcome Address||Shri Sandeep Bhalla, General Manager(Development), JK Paper Limited|
|Special Address||Shri K. K. Chakarvarti, Expert Consultant, Bureau of Energy Efficiency|
|Special Address||Shri A. S. Mehta, President, JK Paper Limited|
|Special Address||Shri Simon Petrie, First Secretary, Low Carbon Growth, British High Commission|
|Inaugural Address||Dr. Ajay Mathur, Director General, Bureau of Energy Efficiency|
|Vote of Thanks||Ms. Ritu Bharadwaj, Senior Program Manager, Institute for Industrial Productivity, India|
|TEA BREAK (9.45 AM -10.10 AM)|
|TECHNICAL SESSION I (10.10 AM-1.00 PM): BEST PRACTICE PRESENTATION BY INDUSTRY REPRESENTATIVES|
|Chairman||Shri N K Agarwal, EVP (Works), JK Paper Limited, Unit : CPM|
|PAT Scheme – Pulp & Paper Sector by Bureau of Energy Efficiency||Shri Arijit Sengupta, Assistant Energy Economist|
|ESCerts Trading Mechanism by Bureau of Energy Efficiency|
|Shri Girja Shankar, Assistant Energy Economist|
|REC vs ESCerts Trading by REConnect Energy Solutions Private Limited|
ESCerts for KEP workshop_REconnect
|Shri Anuj Hemant Xess, Manager-Consulting & Operations|
|Best Practices Adopted by JK Paper Limited, Unit: JKPMBest Practices in Energy Efficiency_JKPM_KEP Presentation||Shri Vijay Mantry, VP (Manufacturing)|
|Best Practices adopted by BILT Graphic Paper Products Limited|
|Shri S. B. Sapre, General Manager-Engineering|
|Steam Optimization in Drying Cylinder of Paper Machine by GIZ|
|Shri Arvind Asthana, Senior Technical Expert|
|Best Practices adopted by ITC Limited, PSPD, Unit : Kovai|
Best Practices in Energy Efficiency_ITC Ltd PSPD
|Shri R. Nandha Kumaar, Sr. Manager (Engg.); Shri Rakesh Jaiswal, Deputy Manager|
|Best Practices adopted by JK Paper Limited, Unit : CPM|
Best Practices adopted by JK Paper Limited
|Shri Darab Khan, General Manager (Project & Dev.)|
|Introduction to ISO:50001 & its Implementation by Ballarpur Industries Limited|
ISO-50001_Implementation at Ballarpur Industries
|Shri Rakesh Kumar, Dy. GM|
|Effective Utilization of Biomass to Reduce Carbon Footprint by Harihar Polyfibers, Grasim Industries|
Energy Efficiency Best Practices Harihar Polyfibers_BEE case study
|Shri Manohar Kumar R, General Manager(E&I)|
|LUNCH BREAK (1.00 PM -2.00 PM)|
|TECHNICAL SESSION II (2.00 PM-3.50 PM): ENERGY EFFICIENT TECHNOLOGIES FOR PULP & PAPER SECTOR|
|Chairman||Shri K. Suresh, President, Harihar Polyfibers, Unit of Grasim Industries|
|Cross Learning for Steam Systems by Forbes Marshall|
Cross Learning for Steam Systems by Forbes Marhsal KEP
|Shri Narendra Pratap Singh, Product Manager|
|Energy Efficiency in ETP of a Paper mill by Paques Environmental Technology India Pvt. Ltd|
Energy efficiency in ETPs by Paques
|Shri Willie Driessen, Global Technology & Product Manager|
|Power Plant Optimization through Analysis and Testing by Solvina International AB|
Solvina-Power Plant Optimization
|Shri. Niclas Krantz, Managing Director|
|Advanced Control Solutions for Pulp mill by ABB India Limited|
Pulp Mill Advanced Process Control Solutions by ABB
|Shri Gyanendra N Tripathi, Manager – Sales & Marketing|
|Petroleum Coke Handling and Firing in Rotary Lime Kiln by Agro Pulping Machinery (P) Ltd|
Pet coke use in lime kilns_Agro Pulping Machinery
|Shri G. Ram Manohar, Technical Director|
|Energy Conservation in Compressed Air Systems by Atlas Copco (India) Limited|
Energy conservation in compressed air systems_Atlas Copco - Pulp Paper
|Shri Olivier Vlaeminck, Business Line Manager – India|
|Shri Arnab Maitra, Key Account Manager - India|
|INTRODUCTION TO KEP WEBSITE (3.50 PM- 4.00 PM)|
|KEP Website demo by KEP Secretariat||Shri Gaurav Sharma, Program Officer|
|TEA BREAK (4.00 PM- 4.20 PM)|
|PANEL DISCUSSION (4.20 PM-5.00 PM) : PULP AND PAPER SLG MEMBERS|
|Future Strategies to be adopted; need for promoting innovative, new and cutting edgetechnologies and identify the areas for sharing of Cross- Sectoral Best practices|
|Formation of teams for Friendly Energy Efficiency Exchange visits|
|CONCLUDING REMARKS (5.00 PM- 5.30 PM)|
|Shri Sandeep Bhalla, General Manager(Development), JK Paper Limited,|
|Shri A K Asthana, Sr. Technical Expert, GIZ,|
|Ms. Ritu Bharadwaj, Senior Program Manager, IIP India & Shri K. K. Chakarvarti, Expert Consultant, Bureau of Energy Efficiency|