CII National Award for

“Excellence in Energy Management - 2017”

ITC Limited, PSPD, Unit - Kovai

ITC Ltd. , PSPD , Unit: Kovai is located 42 km North of Coimbatore, Tamil Nadu

Acquired from BIPCO in March 2004

Manufacture Duplex Board from 100 % recycled fiber

Production capacity of 1,20,000 Tons / year

Employment to 1000+ people

Certifications:

ISO 9001 : 2015; ISO 14001 : 2015; OSHAS 18001 : 2007

Certified for Forest Stewardship Council (FSC)

First Indian Manufacturing unit to gain WWF’s Global Forest Trade NetworkMembership

ITC PSPD Unit Kovai – First Company in the Pulp and Paper Sector to receiveGreenCo Platinum rating

Under GREEN POLICY, ITC Kovai is committed to monitor and improve our efforts fora cleaner environment and a better future for everyone

CII Excellent Energy Efficient Unit 2010, ’14, ‘15

Mill Introduction

Process Flow

TL wire

Coater Dryers,

MG, Calender

Board machine

ETPTreated Effluent

for Irrigation

Petax Filter

Cogen 8MW

Steam

Water from River

Condensate

FuelEmission:

SPM <30ppm

Sp. Water: 9.8 m3/T

Reel & Rewinder

She

eter

s

Finishing House

Despatch

Stock Preparation

PulperWaste Paper

ScreenCentri cleanerHot disperser

FL wirePulperWaste Paper

ScreenCentricleanerHot disperser

BL wirePulperWaste Paper

ScreenCentricleanerHot disperser

Water Treatment

DM Plant

Press&

TemsecRewinder

Sp. Power: 588 Units/T

Treated Effluent Reuse

TSS <30ppm

Windmill 7.5MW

Sp. Discharge = 5.5 m3/ MT

TG8 MW

Board M/C Q = 21TPH

Stock prep Q = 2.5TPH

VAM Q =0.3TPH

Thermo compressor Q=2.4TPH

Air tunnels Q=3.2TPH

HP SteamQ=43.4 TPH

LP Ext Q=29.8 TPH

MP Bleed Q=5.6 TPH

Stock Preparation – 222 kWh/ ton

Board Machine & CCK – 229 kWh/ton

Utilities –91.4 kWh/ ton

Finishing house – 10.3 kWh/ ton

HVAC & Lighting – 7.1 kWh / ton

Intake pump house– 5.2 kWh /ton

Mill Overall Energy Balance

Deaerator Q = 6TPH

To condenser Q = 8TPH

Windmill 7.5MW

5 MW 2.5 MW

600

588 586

565

550

560

570

580

590

600

610

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

Specific Power (kWh/MT of FNP)

5.8% Reduction

2.51

2.39 2.39

2.32

2.20

2.25

2.30

2.35

2.40

2.45

2.50

2.55

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

Specific Steam (MT/MT of FNP)

7.6% Reduction

Cycle 1 - PAT Performance (MTOE/T)

0.34800.3410

0.2900

0.2600

0.2700

0.2800

0.2900

0.3000

0.3100

0.3200

0.3300

0.3400

0.3500

0.3600

Baseline Target 2014-15

Unit Kovai Power Source (%)

Comparison Bio-fuels in 2016-17

59% 27%

CO4

DOB

Saw Dust

Charcoal Powder

Saw Dust

Bio-fuels in 2013-14

13 2039 42

2331

59 5437

27

0 0

0%

20%

40%

60%

80%

100%

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

Cogen Biomass Windmill Cogen fossil State EB

73% Power Source was Renewable in 2016-17

Summary of Energy Savings & Investment

YearSum of Annual Energy

savings (Lakh Units)

Sum of Total Annual Savings

(Rs Lakhs)

Sum of Invest. Made

(Rs Lakhs)

Payback(Months)

2016-17 17.9 84.2 76.8 11

2015-16 9.82 49.1 65.2 16

2014-15 15.35 53.74 66.25 15

Total 43.07 187.04 208.25 13

YearSum of Annual Steam

savings (Tonnes)

Sum of Total Annual Savings

(Rs Lakhs)

Sum of Invest. Made

(Rs Lakhs)

Payback(Months)

2016-17 503 15 44.5 36

2015-16 1275 38.27 148 46

2014-15 2140 21.4 34 19

Total 3915 74.67 226.5 36

Steam

Power

Innovative Project – 1 (Internal EnCon idea)Replacement of traditional Starch Agitators with Efficient One

Past Scenario :

Coating Kitchen Starch Preparation Agitators were installed in 1995 & it was operating with 30KW motor.

It was not looked as Energy Saving Potential Equipment for last so many years.

Present Scenario:

Through technology advancement, we were able to identify a suitable agitator which can reduce power consumption by 97%.

Energy savings 425 Units/Day

Investment 3.5 Lakhs

Payback 6 Months

EquipBefore

KWAfterKW

Starch Tank 2 Agitator 30 0.75

Modified Design

97%

Reduction

Innovative Project – 2 (Internal EnCon idea)Replacement of 52 Nos MH Lamp with 18Nos Plasma

Past Scenario :In our Finishing House & Godown, we were

using 52Nos of 250W Metal halide Lamps for internal lighting. MH lamps are in efficient & it also requires lot of Maintenance. One team use to work continuously for lighting maintenance.

Present Scenario:LEP (Light Emitting Plasma) lamps were

installed in Himast and technology was explored for Hibay lamps. We were able to reduce 52Nos of MH light fittings with 18Nos 260W Plasma lamps.

• Energy Savings 70%• Its maintenance free also.

Project Summary:

Energy Savings 131 Units/Day

Investment 11.7 Lakhs

Payback 5.4 Years

CO2 Emission Reduction

• Plant Details - 8MW Cogeneration with 60TPH steam generator.

• Fuel used: Predominately Biomass Co-fired with fossil fuel.

– Biomass : De-oiled Rice Bran, Saw Dust, Wood Chips, Charcoal dust

– Fossil Fuel: Coal, Lignite

– Biomass consumption: 75K MT (2016-17)

Utilization of Agro Residue Biomass in Co-Generation System:

• Plant Details – 1.5MW X 5 Nos = 7.5MW Windmill

• 200 Lac Units Generation Potential / Annum

Utilization of renewable Windmill Power for Production

Energy Efficient Agitators & Aerator

Title of Energy Saving project implementedYear of

Implementation

Annual Energy savings (LakhUnits)

Total Annual Savings

Invest. Made Payback

months

Rs Lakhs Rs Lakhs

Energy Saving Agitator for FL Blend Chest2016-17

0.63 2.9488.12 33

Energy Saving Agitator for FL HD TOWER2016-17

0.59 2.7528.12 35

Energy Efficient Aerators for ETP2016-17

6.93 32.43225.8 10

Total 8.15 38.13 42.04 13

Energy Efficient Lighting & MotorReplacement of 150 Office Lights with 36W LED 2016-17 0.32 1.52 3.9 31

Energy Efficient IE3 Motor for Mini Press 2016-17 0.02 0.12 0.16 17

Total 0.34 1.64 4.06 29

Energy Efficient Pumps (Part 1)

Title of Energy Saving project implementedYear of

Implementation

Annual Energy savings (LakhUnits)

Total Annual Savings

Invest. Made Payback

months

Rs Lakhs Rs Lakhs

Energy Efficient Makeup water pump 2016-17 0.34 1.589 1.117 8

Energy Efficient Recovery fibre chest pump 2016-17 0.27 1.278 1.12 11

Energy Efficient Vac Cooling Tower pump 2016-17 0.12 0.550 1.75 38

Energy Efficient Process Cooling water Pump 2016-17 0.77 3.589 1.72 6

Energy Efficient Vacuum hot well pump 2016-17 0.17 0.814 3.92 58

Energy Efficient Krofta Feed Pump 2016-17 1.36 6.369 1.98 4

Energy Efficient New SS Tank Feed Pump 2016-17 1.25 5.846 1.8 4

Energy Efficient Pumps (Cont)

Title of Energy Saving project implementedYear of

Implementation

Annual Energy savings (LakhUnits)

Total Annual Savings

Invest. Made Payback

months

Rs Lakhs Rs Lakhs

Energy Efficient Recovered Fiber pump 2016-17 0.21 0.995 1.12 14

Energy Efficient Krofta High Pr Pump 2016-17 1.59 7.442 0.84 1

Energy Efficient CPU Feed Pump UTY 2016-17 0.05 0.244 0.45 22

Energy Efficient UF Feed Pump_Uty 2016-17 0.09 0.427 0.58 16

Energy Efficient RO transfer pump 2016-17 0.09 0.417 1.29 37

Total 6.32 29.56 17.69 7

VFD Applications

Title of Energy Saving project implementedYear of

Implementation

Annual Energy savings (LakhUnits)

Total Annual Savings

Invest. Made Payback

months

Rs Lakhs Rs Lakhs

VFD for Chest no 12 & 13 2016-17 0.70 3.3 1.8 7

VFD for Chest no17 2016-17 0.74 3.5 1.8 6

VFD for Top HD ring dilution pump 2016-17 0.62 2.9 1.8 7

VFD for HD tower pump top 2016-17 0.24 1.1 1.8 19

VFD for Filler blend chest pp Chest 22 2016-17 0.47 2.2 1.8 10

VFD for New TCC feed pump 2016-17 0.20 1.0 1.8 23

VFD for DM2 agitator 2016-17 0.22 1.0 0.82 9

Total 3.19 14.92 11.62 9

List of Major ENCON efforts planned for the next 3 years

S No 8Energy Conservation Action PlanElectrical

(Units/Annum)

Thermal Savings

(Ton of Coal/ Annum)

Lakh Savings / Annum

1 Recovering Bio gas from MLSS & canteen waste 54750 350 47

2 Efficient Vacuum Pumps 525000 25

3 Energy conservation Schemes 297500 14.8

4 Fuel Shed 500 15

5Replacement of inefficient traditional agitators with energy efficient agitators for pulp storage chest

350000 16.2

6Replacement of old pumps with new higher efficiency pumps at identified locations

262500 12.1

7Installation of Variable Frequency Drives for various equipments

400000 18.5

8 Steam system optimisation 500 15

18

250

150131

89 86104 108

0

50

100

150

200

250

300

TNPCB Norm

CPCB Norm

revised

2012-13 2013-14 2014-15 2015-16 2016-17

COD2100

1600

1145 1073 1112 1164 1085

0

500

1000

1500

2000

2500

TNPCB Norm

CPCB Norm

revised

2012-132013-142014-152015-162016-17

TDS

100

3040.2 39

31.9 27.9 25.6

0

20

40

60

80

100

120

TNPCB Norm

CPCB Norm

revised

2012-132013-142014-152015-162016-17

TSS30

20

7.7 7.6 6 5.5 5.6

0

5

10

15

20

25

30

35

TNPCB Norm

CPCB Norm

revised

2012-13 2013-14 2014-15 2015-16 2016-17

BOD

Waste Management – ETP Water

Utilization of Waste Material

ETP Sludge

• 100% sludge generated is reused in process

Process Plastics Waste

• 100% sent to cement plants to Co-process in kiln

Fly Ash

• 100% fly ash generated sent to recycled for fly ash brick making

Energy Conservation Projects Generation

• TPM (Lean Manufacturing)

- Kaizen

- Focused Improvement Projects

• Energy cell

- Internal Audits (By Energy cell members)

- External Audits (By Third Party)

- Campaigns

ENERGY MANAGEMENT CELL KPOV’s 17-181) Targets

• Power Reduction: 61 units/ Tonne of FNP

• Steam Reduction: 0.36 Tonne/ Tonne of FNP

2) Energy Audits planned for 2017-18: Vacuum system Audit

3) Identification of one Encon Project per month and co-ordination for implementation.

4) Knowledge sharing on energy conservation – Minimum two per month

S No Name Specialist Area of focus

1 R Muralidaran Energy Manager Overall

2 P Premaguru Utility AET- Process Specialist Water

3 D Ranjith Kumar Stock Preparation AET- Engg Specialist Power

4 V Abinesh Stock Preparation AET- Eng Specialist Power & Steam

5 TK Jegadish Board Machine AET- Process Specialist Power & Steam

6 Jasper Devapaul Board Machine AET- Engg Specialist Power & Steam

7 N Vijayakumar Finishing House AET - Engg Specialist Air

8 M Phaneendhra Utility AET- Engg Specialist Power

Energy Cell Members & Role

Energy Cell Celebrations

• Energy Conservation Day

• World Water Day

• World Environmental Day

• Ozone Day

S No Title of ProjectYear of

implementation

Name of Associate/Vendor

Energy Unit

Energy consumptio

n before project

Energy consumpti

on after project

% Improve

ment

1Encouraging & Coordinating vendors for GreenCo certification

2016-17 Fimakem NA NA NA na

2Increase in productivity of the Sheet cutter

2014-15Suriya Cutting

WorkskWh/

MT4 3 17.95%

3Reduction of Environmental Impact

2014-15 FimachemkWh/ Day

11002 9793 10.99%

4To Replace old motors with new IE2 motors.

2013-14

M/s.ManoramaPradhan Paper and Board – Karamadai

kWh 45 34 24.44%

5Replacement of Old Earth moving vehicle with energy efficient vehicle

2013-14Coimbatore Earth

Movers

Liters of Diesel/

Day128 96 25.00%

EnCon Projects implemented by Associates/ Vendors

First Greenco – Platinum rated Paper Mill in India, 2015 CII National Award

Safety award -2012 & 2015 National Safety Council of India

Productivity Award 2013, ‘14 Coimbatore Productivity Council

Excellent in Energy Management 2014, ‘15 , ‘16 CII National Award

Best Environmental performance-Innovative Project, 2013 CII National Award

1st Position at Green Award 2013 TNPCB, Government of Tamil Nadu

2nd Position at Green Award 2014 TNPCB, Government of Tamil Nadu

EHS Excellence Award, 2013 CII National Award

5 Star Safety Rating, 2007, ’08,’10,’11 British Safety Council

5 Star Environment Rating, 2011 British Safety Council

International Safety Award, 2010 British Safety Council

Globe of Honor for Environment,2011 British Safety Council

Excellent Water Efficient Unit, 2007, ‘08, ‘09, ‘11 CII National Award

Excellent Energy Management, 2010, 14, 15 CII National Award

National Energy Conservation Award, 2010 Bureau of Energy Efficiency24

AWARDS & ACHIEVEMENTS

THANK YOU