RAMA NEWSPRINT

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RAMA NEWSPRINT PAPERS LTD SURAT
Presented by C. D. Dalal Engineer-Energy
Conservation Pramod Kumar Dy. Manager- Process
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INTRODUCTION

• M/s. Rama Newsprint and Papers Ltd. is engaged in
  the business of manufacturing Newsprint and
  writing and printing paper, with an installed
  capacity of 1,50,000 MT per annum.
• This is a Enviro Friendly Green Field Recycled
  Based Project situated at vill. Barbodhan, Tal.
  Olpad, Dist. Surat, Gujarat State.

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Paper Machine 1
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Paper Machine 2
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DEINKING PLANT
Sl No Plant Description Capacity
01 Washing Deinking Plant (existing)   230 MT/Day
02 Floatation Deinking Plant (existing) 170 MT/Day
03 Floatation Deinking Plant (proposed) 600 MT/Day
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BOILERS
Sl. No. Description Item/Section Design Pressure (Kg/Cm2) Design Temperature (oC) Max. Continuous Rating (TPH)
1 Multi-fuel Boiler3(AP-2) 84 483 90
2 Multi-fuel Boiler4(CE-4) 84 483 107
3 Oil fired Boiler(OK-8) 64 480 60
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TURBINES
Sl. No. Description Type Inlet Steam Pressure Inlet Steam Temperature Capacity
1 SIEMENS TG (TG2) Condensing 35 kg/cm2(g) 410 oC 8 MW
2 AEG TG (TG1) Extraction cum back pressure 82 kg/cm2(g) 480 oC 15 MW
3 BHEL TG (TG3) Extraction cum condensing 81 kg/cm2(g) 470 oC 23 MW
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BHEL 23 MW TURBO GENERATOR
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ORGANIZATION CHARTENERGY CONSERVATION CELL
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NEED FOR ENERGY CONSERVATION

• RNPL was established in 1996.
• As new technologies came, RNPL accepted them
  modified the old one. so some process parameters
  changed.
• New technologies also came in Energy Conservation
  Field.
• Awareness increased towards Energy Conservation.

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ENERGY CONSERVATION ACTIVITIES IN PAPER MACHINES
Sr. No Description Saving Quantity (per Year) Saving (Rs/Year)
1 Interlocking PV steam with PM1 Steam 500 MT 2,29,500/-
2 Reducing running hrs of Refiner in PM1 Power 13,86,000 KWh 27,72,000/-
3 By passing Broke chest pump agitator Power 8,07,840 KWh 16,15,680/-
4 Installation of Krofta in PM2 Power 64,350 KWh Water 3,96,000 m3 30,19,500/-
5 Save Water in Krofta by level adjustment Water 3,96,000 m3 28,90,800/-
6 Steam and condensate system in Paper Machines Power 7,44,480 KWh Steam 4904 MT DM water 4500 m3 39,24,846/-
Total 1,44,52,326/-
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ENERGY CONSERVATION ACTIVITIES IN DEINKING PLANT
Sr. Description Saving (Per Year) Saving (Rs/Year)
1 WDP It was found by monitoring that virtually no difference in pulp quality without Deflaker so stopped 7,12,800 KWh 14,25,600/-
2 By passed Thickener Feed chest pump agitator in FDP 2,72,448 KWh 5,44,896/-
3 Replacing air compressor of 30 KW with 11 KW for Krofta clarifiers 1,66,320 KWh Water23,760 m3 5,06,088/-
4 Using recycled water in Floatation cell sealing cooling gland packing Water47,520 m3 3,46,896/-
5 Stopped Dump chest agitator 1,32,000 KWh 2,64,000/-
6 Replacement of 400 W HPMV lamps by 150 W HPSV lamps in FDP 12000 KWh 24,000/-
7 Stopping Frovi Pulper, Pump Conveyor 16,07,760 KWh 32,15,520/-
Total 63,27,000/-
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ENERGY CONSERVATION ACTIVITIES IN UTILITY
Sr no Description Saving (per Year) Saving (Rs/Yr)
1 Installation of new 23 MW Extraction Condensing Turbine 1255 lacs
2 Using recycled water for ash handling system Water 3,96,000 m3 28,90,800/-
3 Reducing compressed air consumption in Utility by tuning auto time loading time of ash handling system with boiler operation Air 9,90,000 m3 2,97,000/-
4 By diverting bearing cooling water of Boiler Feed Pump jacket cooling water of ash handling system to cooling tower Water 66,000 m3 4,81,800/-
5 Running 4th CT fan only in summer 1,21,000 KWh 2,42,000/-
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Continue
Sr no Description Saving (per Year) Saving (Rs/Yr)
6 Started new BFP of same capacity which consumes less power 2,64,000 KWh 5,28,000/-
7 Trimming of two no of Clear Water Pumps in WTP 1,58,400 KWh 3,16,800/-
8 Replacement of existing pump set in CST transfer pump 1,44,000 KWh 2,88,000/-
9 Condensate Recovery System DM Water 4725 m3 1,89,000/-
Total 1305 lacs
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ENERGY CONSERVATION ACTIVITIES IN OTHER AREAS
Sr. Description Saving (Per Year) Saving (Rs/ Year)
1 Isolation of ideal transformers to save no load loss 40,900 KWh 81,800/-
2 Replacement of cement roof sheets by semi-transparent sheet in go down 21,900 KWh 43,800/-
3 Reducing operating frequency from 50.3 Hz to 49.5 Hz 23,76,000 KWh 47,52,000/-
4 Continuously monitoring for minimize leakages and wastage - -
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ENERGY CONSERVATION PROJECTS UNDER PROGRESS
Sr. No Description Saving (Per Year) Net Saving (Rs/Year)
1 Modification in Stock preparation system by passing 3 chests. 3,92,000 KWh 7,84,000/-
2 Interlocking of PV steam with PM2 Steam 900 MT 4,13,100/-
3 Sealing water of vacuum condenser to be diverted to Warm Water Tank Water 75,900 m3 5,54,000/-
4 Access water from Warm Water Tank to be transferred to Water Treatment Plant Water 66,000 m3 4,52,000/-
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Continue
Sr. No Description Saving (Per Year) Net Saving (Rs/Year)
5 Air chiller to be installed in compressed air line going for Calendar cooling. 3,16,800 KWh 5,48,000/-
6 Mega Booster to be put in ash handling system 9,90,000 m3 2,15,000/-
7 Energy Audit performance contract Profit Sharing Basis Profit Sharing Basis
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SPECIFIC STEAM CONSUMPTION IN NEWSPRINT PRODUCTION
Target for 2006-07 5.75 MT/MT
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SPECIFIC POWER CONSUMPTION IN NEWSPRINT PRODUCTION
Target for 2006-07 991 KWh/MT
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SPECIFIC WATER CONSUMPTION IN NEWSPRINT PRODUCTION
Target for 2006-07 30 M3/MT
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SPECIFIC TOTAL ENERGY CONSUMPTION IN NEWSPRINT
PRODUCTION
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VISION 1000 MT PRODUCTION PER DAY EXPANSION
PLAN OF 1,50,000 MT/ANNUM  OVERALL
PRODUCTION P.M. 1 -- 70,000
MT/ANNUMP.M. 2 -- 80,000
MT/ANNUMP.M. 3 -- 1,50,000
MT/ANNUM
(PROPOSED)
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TOTAL. 3,00,000 MT/ANNUM

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THANK YOU